Fully articulated and comprehensive air and fluid distribution, metering, and control method and apparatus for primary movers, heat exchangers, and terminal flow devices

ABSTRACT

The described method and apparatus pertains namely to the HVAC (Heating, Ventilating, and Air Conditioning) industry, though its many functions extend into any and all forms of air-fluid movement, metering, distribution, and containment. Essentially, the scope of operation of the method and apparatus encompasses all forms of scientific and engineering measurement dealing with fluid dynamics, fluid statics, fluid mechanics, thermal dynamics, and mechanical engineering as they pertain to precise, articulated control of air-fluid distribution and delivery. The described method and apparatus offers complete, comprehensive, and correct utilization of air-fluid movers and terminal devices under unique sensor logic control, from initial lab testing stages through to equipment cataloguing, selection, design and construction of any and all air-fluid distribution systems in entirety, whereas previously there was no such cohesive, total and terminal method of control for these systems or their components.

CROSS-REFERENCE TO RELATED APPLICATIONS

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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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REFERENCE TO SEQUENCE LISTING

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BACKGROUND OF THE INVENTION

The method and apparatus of controlling air-fluid distribution and heatexchange may apply to any commercial, industrial, scientific, orengineering application wherein air flow, fluid flow, gas flow,containment or mixture thereof would require most efficient, mostprecise distribution, articulation, and delivery. However, the mainapplication as described herein will namely address the HVAC (Heating,Ventilating, Air Conditioning) industry.

The following description and claims are supported by established factsknown from scientific and engineering principles as set forth by thelaws of fluid dynamics, fluid statics, thermal dynamics, affinity laws,and by building and energy codes.

The Primary Mover

The first step in the process of determining system status begins withthe primary mover and air handler (or fluid handler) itself, includingall of its internal components. Referring to FIG. 2, 2A, 2B, theseillustrations depict an “old school” arrangement of mover testing forTP, SP, and Vp (Total Pressure, Static Pressure, and Velocity Pressure[of mover.]) It will establish a premise of known methodology, whichwill be referred to throughout the specification.

The various testing elements (probes) are arranged at the center of eachduct. Note that there is no indication of whether these are meant tosuggest a traverse of each duct or a testing at their cross-sectionalcenter points (V-max or maximum velocity.) This also becomes moot whenviewing FIG. 2A, as a true static pressure acts laterally against thewalls of a duct, not over its cross-section, though some negligibleforce may be sensed there with a static probe. It would then, therefore,be logical to state that where the velocity is maximal, the staticpressure would be minimal. The other assumption in this sensingarrangement is that the cross sections of discharge and suction havelaminar flow, which in the case of most centrifugal fans, it certainlywould not, particularly on its inlet side in close proximity to the fan.This is why sensors and flow stations must be located a sufficientdistance downstream or upstream of the mover and with adequate straightsection of duct or piping run.

Ready comparisons may be drawn between these early figures and FIG. 13,14, 14A, 14B, primary mover sensor logic as employed by the describedmethod and apparatus, which takes these fundamentals further andbroadens their scope. These are schematic depictions of the sensorarrangements whose actual configuration may differ in appearance, thoughthe principle function remains. Various sensor stations, assemblies, and“grids,” as we will call them, currently exist that may appear vastlydifferent from either an equal area or log traverse, though thecomprising elements (static, impact sensors) must be the same or theymust be incorrect, though they may be somewhat functional withcorrective calibration. References are made according to known andaccepted methods of testing.

Referring also to FIG. 15, 15A, 15B, terminal or in-line device sensorlogic, one key difference between a mover and its terminal device whenmaking a dynamic (Vp) comparison under lab conditions with no systemattached, is that the mover's flow-volume can only be measured on oneside. Being an active device and a constant volume machine, itsmanometer reading (or differential) would otherwise equal neutral orzero.

A static differential comparison where a constant volume mover isconcerned will be contingent, as this will be largely dependent onwhether the inlet remains open to atmosphere (entirely in the form ofvelocity and, thus, negated) or ducted to some degree. Additionally, thepercent “wide open” testing will have an impact on this arrangement. Asdifferent degrees (or percentages) of closure are applied to the mover,the static content will shift more from one side to another undervarying conditions. Its total amount will remain potentially, butconversion and shifting will occur. And, this will affect namely howmuch “system” may be applied to the suction of the mover, where systemdesign length of run per cross-section is concerned. The optional sensorarrangements shown have to do with already packaged or housed existingsystems that may incur SP or Vp losses on one or the other side of themover.

Undoubtedly, the type of mover will have an impact on test methods. Forexample, an axial fan or positive displacement pump will lean towardspressure constancy inlet to outlet, while centrifugal movers willexhibit more flexibility because of the nature of their construction andthe forces at work. Mover aside, the described methodology clearly holdsfor the terminal device, particularly through its range of motion andwith the mover's total power applied as a constant or variable.

One key difference in the diagram shown in FIGS. 2, 2A, and 2B, is thatthe SP and Vp readings in determining “Fan SP” and “Fan Vp” seem to beslanted toward only the discharge of the mover, in so far as each isconcerned. This probably assumes inlet open to atmosphere (100% dynamicflow) on the mover's suction side with little or no ducting, ideallysuited to an open plenum return, perhaps. Lab testing standardstypically use this condition: open inlet with ducted discharge.

In the case of FIG. 2, it is safe to assume that the dynamic aspect isnegated by the total impact sensing on the inlet, though this negates SPon this side as well, especially once ducted and how ducted. Typicallyspeaking, however, when one side of a mover is 0.00″ WC static (or 100%velocity,) the other side is deemed to be 100% of its static power. Butanalyzing these effects are crucial to avoiding the pitfalls ofpresumption.

Additionally, the arrangement doesn't account for 1) System Effectlosses once the mover is fitted and packaged. 2) The characteristicductwork, namely on the suction side and the effect it will have on themover, totally speaking. 3) There is no apparent reference to atmospherewherein TP and SP are concerned, and establishing this may be difficultconsidering that the interior of building envelopes will taint theresults, for the very reasons described in this specification.

The aim here, however, is not to play out differences, but ratherdescribe how the said method and apparatus refers to known principlesand progresses from these as a valid starting point to those alreadyschooled in “the art” and provide a logical background to itsdevelopment for clearer understanding.

The Fan Total Pressure

The Fan Total Pressure is a core measurement of the primary mover'stotal strength or total muscle, internally speaking. This determinationis crucial to sizing the air-fluid distribution system in its entirety,full circle—discharge to suction—and, subsequently, establishing therepresentative system curve connected to the primary mover. This readingis taken directly at the mover's inlet and outlet with no other elementsbetween. FIG. 3 shows a schematic of a typical “draw-through” unit withthis demarcation and others delineated across its profile.

As shown in this example of a typically packaged or housed system, eachcomponent has a section. Firstly, we find the mixing box, where returnair and outdoor air enter and mix airstreams; or simply return airalone, whether in the form of 100% return air or containing somepercentage of outdoor air content. It may also contain an added airstream or fluid content supplied (ducted in) at some point upstream. Thenext section, moving in the direction of suction flow, is typically afilter or pre-filter section, followed by the cooling or heating coilitself, where primary heat exchange takes place. Following these, theblower cabinet and, finally, discharge. In some cases, there may beadditional segments aft of the blower (filters, additional coils, etc.)It is here, however, exactly at the primary mover's inlet, where onesensor grid is connected and the other at the fan's discharge indetermining a Fan Total Pressure.

In the past, with “built up” systems, i.e. systems that didn't arrivefrom the manufacturer with cabinets and housings, but were rather justblowers, motors, drives, and other basic components for field assembly,the traditional method of determining Total Fan Power was to arrange animpact tube (total pressure sensing element) at both the fan's ductedinlet and its ducted discharge. For a proper “Fan Total Pressure” to betaken, these two impact tubes were connected directly to a manometer(HI+ and LO−) and, hence, the total “muscle” of the blower wasdetermined by the manometer differential in “WC or “WG units (samedenotation.) Similarly, a “Fan Static Pressure,” to use generic terms,would be determined by a static sensor at its outlet, minus totalpressure (impact sensor) at its inlet as a differential across bothmanometer connections. Again, refer to FIGS. 2 and 2A.

However, with modern “packaged” systems, blower mounting and housinginside of a cabinet has made this process vary considerably. Forpractical purposes, the new meaning accepted or simply understood bymanufacturers and design engineers is that the blower's “Total Pressure”is simply measured as two “added” static pressure readings directly atthe blower inlet and its discharge, these actually being subtracted(differentiated) as a negative and positive; for example, +5 “WC read atoutlet minus −5 “WC at suction inlet equaling 10 (5−−5, or 5+5, a doublenegative thus added.) This can also be thought of as two absolutevalues, since it represents the fan's total power, coming and goingcombined.

Though technically, this is not the tried and true method, since it onlyconsiders static forces and not dynamic ones, it is the widely usedmethod and has been employed for practical field measurement purposes,so long as the manufacturer's, design engineer's, and balancing agency'sunderstandings are the same, thus the idea is corroborated and theintentions are the same. The design engineer, manufacturer, andbalancers, however, should be aware of this fact for seriousconsideration when selecting, supplying, and testing the equipment,respectively, so the dynamic aspect of this equation is not overlooked.This point is stressed by the known fact that field measured StaticPressure readings are considered among the least reliable data in anexisting or “as-built” system.

Furthermore, the immediate discharge in close proximity to a blower isprimarily in the form of pure, non-uniform velocity, until static regainoccurs approximately ⅔ of the way into the system, when there is asystem. This fact alone may contribute to misleading or misinterpretedtest results as well. Though in terms of static measurement, a higherstatic reading will occur at the enclosed inlet to somewhat compensatefor this, reflecting the fan's total static power if only on one side,and with the added proviso that those are the terms agreed upon.

The recommended standard for testing any type of fluid flow is auniform, stable condition known as laminar flow, normally occurring 2.5duct widths for every 2500 FPM or less of discharge velocity from amover and 1 additional duct width for every additional 1000 FPM. It isalso accepted that there should be no more than 15 degrees converging or7 degrees diverging in any fittings under such conditions. This is anequivalent round duct diameter, whereby a rectangular fitting would beconverted through: SQ. RT. 41w/PI. This criterion is also known as the100% effective duct length, through which it is supposed that the totaleffectiveness of the mover may be realized.

The traditional method (two impact tubes) may have been employed wheresuch systems offered an inlet duct run directly into the blower inletwhere possible. In-line axial and radial-type centrifugal fans, bothbeing ducted in series, end to end, may have been tested this way, solong as differences were noted and understood when compared todissimilar systems. Those skilled and experienced in the art, such asHVAC engineers or Testing & Balancing Supervisors should be aware ofthese differences.

It is understood, for example, that packaged units are assigned an ESP(External Static Pressure) and that simpler movers, such as fans with nofilters, coils, or other sectional devices fore or aft of the moveritself are understood to be assigned with what is both an ESP and TSP(Total Static Pressure,) these becoming one and the same concept becauseof no internal component losses coming into play.

These concepts still remain the source of much debate in the industry,and as a result, no consistent air-fluid distribution control system hasbeen adequately or consummately applied, but rather the emphasis hasbeen more on temperature control alone. Aside from this fact alone, thisis true for many more reasons, which will be discussed in varioussections of the following specification.

Practically speaking, this outdated terminology will be cited morecarefully since it produces a conflict in terms: Total Pressure, TotalFan Pressure, and Total Static Pressure, the latter being the newerterm, as normally understood. The method and apparatus described here,however, does, in fact, take the dynamic side of the equation intoaccount throughout the system as a whole, from main runs to terminalruns as will be described in great detail in the following sections, asthis is a key basis of its operation in whole and part.

Catalogued fan systems typically present tabulated or plotted fan dataas Total Static Pressure for all intents and purposes and, as a result,the velocity factor is considered secondary, usually assumed as a safetyfactor. Though a keen design engineer may be aware of this and accountfor it in the equipment selection and specifications, it is the basis ofthe following description to emphasize the significance of this velocityfactor or “gradient” as it pertains to system operation, after a systemis installed and is purported to be under some degree of automatedcontrol under normal operation, after the fact.

The Packaged Unit's Total External Pressure

The packaged system's External Static Pressure is, again, a differentialof static pressure at the primary system's most exterior intake (beforepre-filter section) to its most external discharge side. The purpose ofthis is to establish the surmountable losses of all internal componentswithin the packaged system, blower itself aside. In basic terms, thismeasurement is taken from end to end of a packaged unit. Note FIG. 3

Many manufacturers apply this figure instead of what is normallyunderstood as the “Total Static Pressure” of the blower or primarymover. This may be a source of confusion as well, though it may arguablybe considered a better starting point in selecting equipment, since italready includes the packaged air handler's own internal losses, whichthe primary mover must overcome before dealing with any systemductwork/piping/vessel to which it will be connected. For convenience,the engineer, then, need not include additional losses for the internalhousing of these systems, though should again be aware of movercharacteristics being the heart of a system and the dynamic aspect ofthis problem, both internally and externally.

The Static Pressure Profile

Beginning from the negative (suction) side intake, a profile is producedwith a static, single-point measurement of each key section of thesystem, sequentially following the path of airflow through to its finaldischarge into the supply air plenum/duct. FIG. 3 delineates locationsfor each static pressure sensing point, though these single point oraveraged readings, when possible, are taken laterally against thehousing wall.

The purpose of this is to obtain pressure drops across each definedsection within the packaged system to determine any effectual changestherein as a more detailed analysis. For example, a filter section'spressure drop will rise considerably after it is “loaded” or saturatedwith dirt and particulate matter. A wet coil will produce a higherpressure-drop than a dry one. These, among other things, will affecttotal system performance, as well as provide key indicators as to thecause of specific deficiencies and where they originate from within thesystem. They may point out, for example, the need for a filter change orcoil fin cleaning. The type and condition of internal components alsoaffect the primary mover with regard to its ability to deal with anychanges occurring external to itself over time and under differing loadconditions of cooling, heating, modulating damper control in the mixingbox, or other unforeseeable obstructions placed there. Conversely,pressure loss (leakage or undue flow) may be noted there as well.

Normal Mode vs Smoke Mode Operation

A common oversight in system design involves improperly sizing orequipping a primary mover for all ranges of motion that a mixing box,face-bypass, or other damper control system internal to the unit housingundergoes. This range of motion alters the pressure profile and mayplace more or less system curve load onto the primary mover. Oneexample: If a primary/secondary air handling system is equipped withboth normal mode and smoke mode operation, it will normally producemixed air (returning and outdoor air combined) at its mixing box to beinjected into the building, primary air being the outdoor air portion asbuilding codes and occupancy would dictate. Under smoke mode operation,however, the return air damper closes to 0% and the system will inject100% fresh air (primary air) into the building to purge smoke, and towork in cooperation with a smoke evacuation fan or other such system insmoke removal. As shown in the following figures, when the path, amount,and temperature/density of entering air shifts from one route to anotheron the suction side of the unit, the system undergoes a drastic change.FIG. 4 shows normal mode operation within a mixing box, and FIG. 4Ashows what typical changes occur in smoke mode operation.

Total Power Available and Required

The key problem arising in the above example is caused by the shift fromone duct system to another, each of which has a completely differentsystem curve assigned to it on the suction side and, thus, as a wholesystem. Adding to this, this is the side where special dynamic losses,known as System Effect losses, most impact the performance of theprimary mover in an adverse way. Unlike most losses, these system effectlosses associated with dynamic flow occur in such a way that they arenot recoverable at any point in the system. They also distort the trueperformance of the mover and/or system curve. It should be noted thatthese unique losses cannot be identified by field measurement, only byvisual inspection from an experienced Testing and Balancing orEngineering Supervisor.

To begin with, the primary mover and packaged system must be sizedbearing the above stated facts in mind, then must be adapted to operatewithin the framework of changing system conditions. For example,adjustment to minimum conditions should never allow full damper closuredue to the necessity of maintaining minimum outside air requirements andfree flow (one way or another) that also prevents the suction sideductwork from collapsing, if conversion to 100% suction static pressureor close to it should occur. Ultimately, the correct and final sizing ofthe primary mover is normally based on the following conditions: lowestminimum outdoor air setting and proportionally minimum return airsetting to maintain fresh air and re-circulated air requirements asdesign and code would dictate. Normally, return air is a fixed settingin its maximum position. Since the advent of single blower systems forsupply and return in a single unit housing, most ducted returns fallshort of design rates before they would ever increase and, thus, seldomnecessitate throttling. This will be further explained in ductwork andfitting losses. Here, the term minimum return air setting provides themost restrictive scenario that a mover might have to contend with,though any additional losses imposed, especially on the suction side ofa system should be avoided if not absolutely necessary, again referringto System Effect losses. This could also greatly impact the sizing ofthe primary mover for little or no reason, further complicated by theeffect loss.

Once all total system changes and the normal operating state is clearlydetermined, the above settings, then, establish the total system curve.This includes all fitted ductwork to and from an established criticalrun—main and terminal branches intact—needed to be supplied, delivered,and returned by the primary mover to operate at design flow rates,totally and terminally, under maximum demand conditions. Where avariable system is concerned, minimum rates manifest themselves in theform of a system diversity factor, which is further noted.

First and foremost, establishing this initial operating point canprevent the largest and least solvable problem in the initial makings ofan entire air or fluid distribution system: over-sizing or under-sizingof total system power required from a primary mover.

Primary Air/Secondary Air Variations

It should be noted that some systems operate only as secondary systems(100% RA, Re-circulated Air or Return Air,) while other systems supplyonly 100% OA (Outdoor Air,) these being primary systems. Most commercialsystems use a mixing box to establish the right mixture of both in onepackaged unit, rather than designate another dedicated system to one orthe other purpose. Outdoor air requirements are currently 20 CFM peroccupant in commercial buildings. Keeping outdoor air to its minimumrequirement is generally desirable in seasonal cooling systems, becausemore outdoor air means more humidity entering the building and more loadon the system, thus higher energy demands. Conversely, morere-circulated air means more energy recovered and less load on the airhandling unit or any heat exchange terminal. Newer systems employ amixing box fitted with actuated dampers and sensors which monitor andregulate the entering OA amount when unacceptably high levels of CO2 aresensed in the returning air, this being produced primarily by theexhaling inhabitants of the building. This and other types of controlspresent a similar problem to smoke mode operation where the system curveand total impact on the primary mover is concerned. These automatedsystems also directly affect the amount of re-circulated air and causeconstantly fluctuating conditions, especially in a VAV (Variable AirVolume) system already plagued with this problem. A modulating OA damperhas a minimum setting, never fully closed unless the mode is unoccupiedor “off-season,” as some systems would have it. This setting reflectsthe code requirement for occupancy, and the maximum setting (full openor a specified design maximum rate) is the position taken when highlevels of CO2 are detected. The OA setting may be the minimum requiredor more, not less. As stated before, the major drawback is that moreOA=more energy load on the system, unless the example is a heatingsystem operating on an economizer cycle, which takes advantage of cooleroutdoor air in such climates. The opposite would then be true, though itis known that hot water systems can maintain as high as 90% of theirheat exchange at 50% of hot water flow. The same is not true of coolingsystems, which always require at least 80% of their (chilled) water flowto maintain adequate heat exchange.

Consequently, the total RA lowers as the OA goes up. The key terms hereare SA (Supply Air,) RA (Return Air,) OA (Outdoor Air.) SA or the totalcapacity (CFM) of the system is made up of the two components: RA+OA=SA.Also, SA−OA=RA, in this case. Therefore, as one goes up, the other goesdown, less total losses or plus gains to the system whole caused bydamper positioning changes, leakage, or other internal losses, such asbypassing or infiltration within the unit housing, particularly thoseequipped with over-sized exhaust fans and relief dampers. The abovecombined or deducted air equation also applies to older twin blowersystems (serving RA and SA independently) when ducted inside the samesystem, without an exhaust (relief system.) Otherwise, this equationbecomes OA=SA−RA+EA when there is an integrated exhaust system.

The Shop Drawing Stage

After a project is approved and building has commenced, the HVAC drawingis usually turned over to a sheet metal fabricator contracted to installthe ductwork as true as possible to the engineer's intended design and,later in the process, a certified Testing and Balancing firm iscontracted to ascertain this fact, among others, by balancing flow rateswithin acceptable tolerances, usually 5-10% plus or minus flow rates atterminal outlets and total rates at primary, secondary, tertiary, etc.,movers at specified loads with minimal losses.

At this shop stage, a shop drawing is usually produced. This isadditional or follow-up drafting work performed by the sheet metalfabricator/installer per “as-built” conditions. It is at this stage,however, that many deviations occur, mainly due to architectural andlogistical changes that were never coordinated/scheduled with the restof the trades on the building project.

This being the case, many fittings, branches, sub-branches are added,taken away, refitted, or entirely omitted as a result. One typicalexample might be caused by electrical conduits that were run prior tothe ductwork being installed and somehow took a wrong turn around wherea light fixture was not supposed to be and, hence, blocked the path ofan air duct, causing two unplanned elbow fittings to be added wherethere was supposed to be straight length of run.

Or, it may simply be that an architect decided that an exhaust outletlouver was not aesthetically pleasing on the observable exterior wall ofa five star hotel, and so additional length and two 90 degree bendfittings were added to avoid this faux paux. Whatever the situation,these can be taken as typical occurrences on every building project withrare exception.

The ultimate effect of these “as-built” revisions results in systemcurves changing, sometimes dramatically. And this is the source of mostproblems on most projects, aside from poorly designed or improperlyinstalled, leaky systems to begin with.

The described method and apparatus may not only assist with thisproblem, but will become a valuable tool for the system designer andinstaller throughout the entire commissioning process.

Over all, the best way to counter these recurring problems is for laterevisions to be made every step of the way and the described method andapparatus can be involved as early as the computer drafting stage withappropriate recalculations and adjustments pre-programmed to the primarymover and terminal device control panel's memory as they areimplemented. Additionally, this process can draw from an entiretabulated database of known equipment, fitting, and performance data asis detailed in this specification. The design operating point will thenadjust accordingly against the known flow-pressure constants of theaptly sized primary mover and terminal device(s.)

Key Terminology

Two key types of devices will be discussed: active devices and passivedevices. Any motor or otherwise kinetically powered, rotating,pulsating, vibrating, flagellating mover (pump, blower, rotor, etc.)will be referred to as an active device, a device producing force and/orkinetic movement. Terminal, in-line, or discharge devices (variable airvolume boxes, valves, monitor stations, diffusers, infusers, registers,grilles, etc.) will be referred to as passive devices. The purpose hereis to distinguish between TP, SP, or Vp as actively generated by amover, or as passively received in an air-fluid stream supplied by thatmover.

In air distribution systems, total pressure and its relationship todynamic losses are expressed as TP(loss)=C×Vp. Total Pressure LossEquals Coefficient×Velocity Pressure, the coefficient being a tabulationof known fitting losses, such as those provided by ASHRAE publications.Piping head loss in hydronics is expressed as H=FLv SQ./2gD.

In hydronics, a Cv (valve flow coefficient) is commonly used for valves,terminal devices, and other fittings; while in air systems, a K factoror Ak factor (including free area) is used for grilles, coil face areas,and other terminal flow devices. The above factors indicate losses asthey specifically pertain to dynamic flow in either medium and will bereferred to as necessary; this to distinguish from provided catalogueddata that would only indicate static pressure drops in inches of watercolumn (or gauge) units and the one-sided myopia this may incur.

With regard to Cv's in hydronics, these represent a flow coefficient ofa valve or terminal/in-line device in its 100% open position with onePSI of pressure drop across the valve or device itself for standardwater, noting that GPM units require no temp./density correction:Cv=GPM/SQ. RT. of Dp (pressure drop must be in PSI units); also,Dp=(GPM/Cv) SQ.; GPM=Cv×SQ. RT. Dp/d (density correction.) Cv's may beestablished for any hydronics device to be used as a flow meter in sofar as catalogued pressure drop data can be relied upon.

K or Ak Factors

Catalogued pressure drops, however, are more in current use in place ofK factors where RGD's (Registers, Grilles, Diffusers) are concerned andperhaps for the better. RGD's are the ultimate terminal devices thatdeliver air-fluid to a given conditioned space. Re-circulated air aside,they are the air/gas/fluid's final destination as far as delivery isconcerned. Pressure drops themselves are perhaps a more convenient ideafrom a design perspective and what it need be concerned with, since Kfactors are now established under field testing conditions, usually by aTesting and Balancing agency. Terminal devices, however, are inherentlydynamic (velocity-oriented) vehicles of air-fluid delivery and should beviewed as such from any standpoint. Due to long time vagaries associatedwith their proper use, however, K factors are seldom seen in cataloguedequipment submittals.

To differentiate the two, a K factor alone is a coefficient associatedwith a given air terminal device, while an Ak, as noted, includes thefree area (cross-section) of that device, factored therewith. At times,these two are used interchangeably, and mistakenly so. This flowcoefficient deals specifically with dynamic losses expressed as adiminished free flow area. The K factor simply whittles down the freearea to a number less than 1 (a perfect square foot of free flow area)for 12×12 RGD's, keeping in mind that free area is already less than onefor those smaller than 12×12. (12×12=144/144=1 sq ft.)

For example, a 12×12 grille (free area of 1) with a K factor of 0.70 (or70%) has an Ak of 0.70×1=0.70. The Ak includes the free area and may bea number greater than one with larger RGD's and, hence, larger freeareas. For example a 12×24 RGD has a free area of 12×24/144=2. If its Kfactor were determined to be 0.65, then its Ak would be 2×0.65=1.30.This applies to terminal outlets greater than 12×12 or equivalent RGD's.

The K factor is determined by measurement at a terminal flowoutlet/inlet with the key equation Q=V×A. Flow equals velocity timesarea. When a “free” flow rate, albeit in a ducted system, is determinedupstream of a terminal or in-line device, along with a face velocity atthe outlet discharge of a terminal device, A (or Ak) may be solved for:A=Q/V. If not a free area cross-section, A represents Ak (A & ktogether) when solved. The K factor alone is not independent of this. Ifit need be known aside from the free area connected with it, it must besolved separately. The known free area is derived from the nominaldimensions of the cross-sectional duct holding the device without itsterminal face RGD, which itself reduces the free area. The K may besolved for alone, or simply put: K=Ak/A

Supply Air vs. Return Air Distribution

In the case of an exhausting or returning air system, the inlet intake(as opposed to outlet discharge) of a terminal device has differingcharacteristics. The flow rate upstream of the terminal/in-line devicewould in this case be on the opposite side, for example, air enteringfrom a conditioned space. This is where free flow rate exists in theform of 100% velocity before encountering the dynamic loss of the RGD.

Velocity readings may then need to be obtained from a traverse of theduct downstream of the grill, moving back toward the primary mover. Theflow rate on the face of an RGD is sometimes taken by a barometer (flowhood) reading covering the inlet. Though more questionable in dischargeair readings due to taking an air measurement at the face of an RGDafter the air stream has already experienced its dynamic losses, thismethod is widely used by balancers to determine K factors for terminaloutlets or inlets out of practical field considerations. Then, ofcourse, Ak=Q (balometer or CFM reading)/V (velocity FPM at RGD face indirection of flow.) Though static and total pressures may have anegative value in exhaust systems relative to atmosphere, velocitypressures or units of velocity, such as FPM, are always thought of aspositive values. They are taken in a closed loop differential, High andLow on a micro-manometer facing the direction of flow.

The disadvantage of this distinctly different path of flow and thereason most ducted return air systems fall short of their required flowrates is that they don't have the benefit of ducted total power, andnamely static pressure behind them (or rather in front of them) prior toexperiencing dynamic losses at the face of their inlets. Leakage ratesare also more pronounced on the RA, or EA suction side, where the Vmax(velocity max) is inverted rather than protruded. This also distorts theactual total fan power being applied effectively, as the leaked airstill returns to the mover. These, then, are the key differences betweenthe two terminal types and bring to light a problem in current systemswith single blower return/supply air. Not to imply that it is impossibleto achieve acceptable tolerances, it simply means much less room forerror in sizing and fitting return air ductwork and in selecting aprimary mover for minimum SA/OA requirements without compromising theRA.

In the case of open plenum (non-ducted) returns, there is less overallrestriction, or more dynamic flow at the expense of high, if notcomplete, pressure loss. Also, there is the distinct disadvantage thatreturn air distribution cannot be precisely controlled, and this isimportant because it is desirable to return air exactly from zones fromwhere it was distributed in equal measure, less any outdoor air, foroptimal recovery. Open systems also suffer from much dirt and outdoorair infiltration from many sources external to the conditioned zones,namely from the equipment room in close proximity to the blower and itsopen intake. Alternatively, direct-ducted RA/OA systems work best forthose that have a smoke control sequence, because less indoor air and,hence, smoke contained therein, may be infiltrated through to theequipment room and re-circulated, despite the best efforts of sealingdoors, ceiling plenums, and other adjacent spaces. Partial ducting, acommon problem, as with transfer ducts, does not improve the situationand cannot work effectively without direct-ducted fan power—a commonoversight in system design. Static pressure is not regained after it islost through broken duct sections and, at best, this provides only asuggestive pattern of functional return flow through leaky ceilingplenums. Typically, open return systems are susceptible to load mixingfrom “crossover” zones, discussed later.

Once the true cross-sectional area of a terminal flow device isdetermined, a non-dimensional velocity passing it (FPM—ft./min., orFPS—ft/sec. in hydronics) is factored to produce a CFM rate of flow(Cubic ft./min.,) or a GPM (gal./min) rate of flow for hydronics, thisafter the FPS is converted to dimensional cubic ft./sec. units and aminute time frame is applied. This may be expressed as: Q=GPM/60×7.49(gal/cu. ft. of standard water); also, V (FPS)=Q (cu. ft./sec)/A(cross-sectional area of pipe size.) And finally, GPM=FPS×A×60×7.49.

Piping sizes for fluid flow use the FPS unit, while air systems andstandard instrumentation for their testing use FPM units. These arefound in traditional tables and charts, which plot head loss againstpiping length, size, flow rate (GPM,) and velocity (FPS) for varioustypes, such as steel, copper, or plastic pipe. Similarly, air ducttables plot friction loss [“WC (inches water column,) or “WG (incheswater gauge) static units] per 100 ft against FPM velocity, flow rate(CFM,) and size of equivalent round duct, this tabulated fromrectangular sizes as these cannot be used directly. Noting for emphasis,both types of charts are plotted against friction loss only (a staticunit of measurement,) as it would relate to length of run, or equivalentlength of run, this to isolate the dynamic aspect of system sizing anddesign which has to do with fitting/directional losses and reduced areacoefficients. This is the industry standard terminology using theinch/pound system, which will be the choice of this specification,though the described method and apparatus may also function in metricequivalent units, if desired.

Among other pitfalls of designing and maintaining an air-fluiddistribution system, the problem with catalogued K factors and any othersuch air-fluid flow coefficients, is that the data may be largelyerroneous due to misrepresentation of actual field conditions, the pointbeing that the K factor is unique to a given system and must beestablished by field testing of that system, as opposed to testsconducted under “ideal,” static lab conditions. This is particularlytrue of plenum box or soffit-type vessels with sidewall registers orgrilles connected perpendicular to airflow and connections generally notin the direction of flow. Many of these infinite dimensional variationswould never or could never be reproduced under lab conditions. In fact,there are simply too many possibilities and variables within a system towarrant such constancy, as it can never be possible, especially with theunpredictable nature of “as-built” conditions caused by late shopchanges to ductwork, capped extensions, turbulence or non-laminar flow,and other un-contoured paths of air-fluid flow.

Another issue with K factors involves their use in VAV systems inadjusting the sensed flow versus actual flow to a terminal branch via aterminal branch device (VAV box, zone damper, valve, etc.) Currently,most leading systems are equipped with adjustment of a K factor or K“value” for given terminal branch flow characteristics. This may beadjusted by a Balancer to calibrate the terminal device's sensor to whatflow is actually not only passing the control device/flow monitorstation, but reaching each terminal outlet, the final destination ofdelivery. The difference of these two, sensed versus actual, indicateslosses due to leakage, dynamic losses, or friction losses—one of thesethree. Normally, the balancer has only to enter the sub-total flowreading he ascertains per outlets for that branch with his own timelycalibrated equipment and enter this data into the control system, whichmakes the basic adjustment: Actual flow/Sensed Flow=K value used toadjust sensor reading and, thus, damper position.

If this value is less than 1, then the flow rate is less than the sensorindicates. If this value is greater than one, flow is more than sensorindicates. The sensor is then calibrated based on this entered datareflecting actual system conditions by calculating a new flowcoefficient that reflects unique system losses for that particularbranch. However simple this process may seem, it still belies the factthat the system must work harder, terminally and totally, to achieve theflow rates due to system losses producing flow factors that may beunacceptably low. Typically, these may fall between 0.65 and 0.80 andrarely, if ever, produce factors at or above 1.

Prior to the balancing procedure, the controls contractor or supplierpresets the terminal device with a factory setting per designspecifications at the outset of the project. In current practice, theterminal device is roughly sized for a flow capacity-range, or at leastas closely as stock sizing will avail. Afterwards, the device seeks toestablish this setting with it own sensing faculties and maintain whatit believes to be the correct setting until it is told otherwise by auser.

The above procedure establishes the main user-control system interfacewhere those skilled in the art are primarily concerned, though a controlcontractor may be more attentive to zone temperature settings andchanges, and, above all, achievement of those settings one way oranother, whereas a Testing and Balancing contractor is concernedprimarily with air-fluid flow rates, in both total capacity and terminalcapacity.

Noted discrepancies between design capacity and actual performance,however, are due to the system characteristics of theductwork/piping/vessel downstream of that terminal device not readilyapparent due to current control sensing limitations. In some cases,improperly placed, connected, or malfunctioning sensors could alsodistort actual conditions. The former may stem from late changes made tothe terminal branch, unexpected losses due to obstructions, acute bendsor turns, changes to sizing of the terminal device for its range andcapacity versus any revised terminal branch system requirements, etc.Additionally, an effect caused by downstream throttling of terminal ortakeoff branches contributes to adverse effects, as this may confusecurrent flow sensors, which, contrary to popular belief, are moreprecise in taking measurements in closer proximity to theterminal/in-line device or flow station at which they are situated.

What Goes In does not Come Out

Consequently, where flow-volume is concerned, “what goes in does notcome out,” contrary to widely held belief. This goes for system total orterminal branch. The difference results from losses in one of threeforms: leakage, friction losses (SP), or dynamic losses (Vp.) Perhapsthe denial exists due to the fact that the primary mover is a “constantvolume machine” as long as rotation is constant. However, aside fromleakage, nothing is truly lost, but rather converted. Curve riding andchanges to a mover (namely speed of rotation) versus changes to a system(length or fitting) also explain this phenomenon. This also stresses theimportance of why these relationships must be viewed in the context ofan operating curve and not independently, as they tend to be.

The key problem, however, lies in the issue of making best use of thisconversion. Much of this has to do with the improper pairing of a moverwith its system, or a terminal device with its sub-system, and theclaims address this problem as supported by this description. Mostcommonly, the losses are a result of leakage, but when the expectedvolume “does not come out,” the remainder may be deemed as staticpressure resulting from undue restriction. Essentially, potential energypent up inside the system is not yet or perhaps never released as flow.It does, however, exist dormant within the system so long as mover poweris applied. The applied force will also exist as long as the ductworkcan contain it for its class and rating. Otherwise, it becomes leakageat one or more points in the system.

One adverse result of this is that more input power must be applied toachieve the same flow rates at terminal outlets. When applieddeliberately, however, static pressure may be manipulated to produceintended results, as is discussed in embodiments. Main and terminalbranch problems are also further examined in the section on “UpstreamLeverage,” an additional supporting claim on the said method andapparatus, and in the section on terminal device flow control and allproblems associated with this.

Overall, the issue of K factors, Cv's, or flow coefficients in generalis an additional supporting concept for the said method and apparatus,referring in particular to terminal devices and their characteristicswithin a given, real system, as opposed to a theoretical one. Labtesting and equipment cataloguing also stand to benefit fromimplementing this method and apparatus at the very outset.

Current Use of ATC: DDC-AD Conversion

Among previously mentioned problems, current DDC (Direct DigitalControls) also suffer from quite severe limitations imposed by theirvery linear nature, namely the linear nature of the micro controllersthey are comprised of, because mechanical, thermal, and fluid dynamicrelationships are anything but linear. This points out another keyadvantage of the described method and apparatus: complex curves andrelationships are plotted first and foremost, then coordinated data isprocessed after this crucial process and other key processing occurs.

Affinity laws alone do not apply to movers outside of a controlledcontext, only theoretically speaking, where direct, squared, and cubedrelationships are concerned. And when they are, they rely heavily uponextrapolation, rather than interpolation. However, where actualfield-testing is concerned, these conditions always vary and stray quiteabroad, especially at low and high ends of the spectrum when dealingwith a lab-tested mover in the constantly changing framework of a real,“as-built” system.

In the proposed system, heat flow is plotted using psychrometricprinciples, namely tabulated data in tenths of degrees. Affinityrelationships governing the mover will be displayed on graphs and areused to plot actual performance curves, as opposed to how they mightperform theoretically at varying positions of WOAF (Wide Open Air Flow.)FIG. 6 and FIG. 6A.

Following this initial pairing of system to mover, true coordinates aredetermined, then translated into readable data as required by alogic-oriented micro-controller. This point also conflicts with currentuse of temperature sensor-oriented controls, which are not governed bythe affinity laws or even thermal dynamics. They simply operate on thedirect linear scale of the micro controller, using single integer math,or operate some form of motor control to effect conditioning changes,normally on a proportional (direct-acting) interface between motorcontrolled damper-actuator and basic sensors. The key problem remains,however, that they go little or no further in obeying the laws ofthermal dynamics or fluid mechanics, or in making use of them forefficiency or effectiveness.

As shown in FIG. 10, the described method and apparatus uses plottedcoordinates established with known affinity laws as a starting point andguided by them whenever unknowns are present. This can then offer acomplete picture where there may be missing links or data unavailable.Following this, the transfer of data inputs and outputs can then beadjusted correctly to perform the necessary functions as required by thehardware. However, this description emphasizes that in using thedescribed method and apparatus, no unknowns will cause an extrapolationto become necessary. Between the breakdown of Total Power and TotalPressure, there shall always be a solid deduction (as opposed toinduction) made never contingent upon unknowns.

Most industrial sensors still require AD (Analog to Digital conversion,)and so are technically not “directly digital,” as the name wouldsuggest. Such sensors still require transduction at some point toconvert an inherently analog signal, for lack of a better term, to acode palatable to a microprocessor. The crux of the problem lies incorrect sensor interpretation and signal utilization. Characteristic andperformance curve plotting based on proper sensor placement, input, andconfiguration is the best approach. This may be done first by truesensor feedback based on correct thermal and fluid mechanics principles,curve plotting, then processing, as explained with said method andapparatus in this specification. Any other method, therefore, must beassumed to be grossly limited, if not wholly incorrect, particularly ifbased on principles of temperature zone sensing and direct dampercontrol alone with localized, unilateral feedback.

In summary, the prevailing difference between the described method andapparatus and current systems lies in temperature control with directdigital motor control alone versus complete fluidic control; thermally,statically, dynamically, and totally.

Key Prime Mover Types and Configurations

Generally, there are two types of movers at either end of a widespectrum: High-pressure type and Low-pressure type. An archetypalexample of a Low-pressure type air mover would be the basic propellerfan or axial fan. Typically, this moves air at a high velocity, highvolume (CFM) and does so at the expense of static pressure. Vane Axialor Tube Axial may be easily confused with Radial in-line fans, which areactually centrifugal and sometimes referred to as the same or may appearsimilar, though they are not. A radial fan's blades don't stem from theshaft, as with a vane or “prop,” but a radial ring of blades rotatesabout the interior housing rim. They are however, SWSI (Single Width,Single Inlet) and in-line with the ducting much like Vane Axials. Themost typical example is the outlet-capped, “mushroom” fan that generateshigh end-suction typically used in rooftop exhausts.

On the opposite side of the spectrum, the centrifugal fan and itsvariants produce higher static pressures with less flow-volume output,comparatively speaking. The FC (Forward Curved) and BI (BackwardInclined) fans are two key types of centrifugal fans, each withdesirable and undesirable characteristics of their own. BI type fans arean example of a higher-pressure type blower, while FC's, used mostcommonly for commercial applications, are a compromise of pressure andflow (or velocity content, which translates to flow.) Most centrifugalsare DWDI (Double Width Double Inlet) for maximum flow-through capacityand air movement volume at given pressures, though even higher-pressuretypes are narrow, single-inlet designs for dust, particle collection, orother high suction vacuum applications. Again, with loss of flow-volumeunder applied motor force, there is pressure gain, whether suction ordischarge. There is also more demand on brake horsepower with thisconfiguration.

Whatever the traits of each type of mover are, its general performancecharacteristics are displayed on a “characteristic curve” and each issuited to a specific application. In current usage, this identifiesspecific qualities and desirable operating points for flow-volume ratesat given static pressures and maximum “static efficiency,” which is aconcept that is flawed from the inception of equipment cataloguing,along with percentage of WOAF, also a static, theoretical projection ofmover-system performance that completely misuses the dynamic gradient.Percentage of closure testing as currently in use has known,acknowledged failures and in no way substitutes for real systemcharacteristics and/or how the mover reacts to those uniquecharacteristics in actual field operation. As currently accepted, mostFC fans' operating ranges fall on their 60% of wide open flow for peakstatic efficiency, still providing adequate flow rates, while BI fanshave a non-overloading (amperage) characteristic and a higher staticefficiency at the expense of lower flow rates. In terms of theirpressure content, the FC fan produces approximately 20% SP (StaticPressure) and 80% Vp (Velocity Pressure,) while the BI fan producesapproximately 70% SP and 30% Vp. This theme of specific flow-pressurecontent will be referred to throughout this specification. FIG. 5 showstypical performance curves for various fans.

The described technology proposes an integrated fluid control unit andmetering device equipped with self-calibration through all system loadvariation as required by changing scalar or vector flow coefficients,including Brake Horsepower, critical Total Pressure, and Critical MassFlow as consummately applied.

In support of this current novelty, many factors place prior art inquestion. One popular misconception in flow testing and mover control isthat the mover's RPM will change as dampering differences or reliefopenings are imposed on a distribution system. For example, one may feelthat if they open an access panel with the blower running—and releaseStatic Pressure—that, along with a notable increase in amperage, themover's rotation will also increase. This is not so. The mover speed ofrotation and unique loading characteristic is independent of the system(unless it is changed in of itself) and it is precisely for this reasonamong others that the relationship must be viewed in a context thatproperly adjusts these changing parameters, further including BHP orTotal KW.

Basically put, changes to one conform to the other in a curve-ridingrelationship along corrected sine/cosine tangents/cotangents. Thisoffers a comprehensive way to control and monitor such a fluid handlingsystem and expect to achieve predictable results. This may also beexpressed through PHI, phase angle on the electrical side, clockingsignal under modulation, or effective damper angle for a valve orterminal device under modulation.

Variable geometry also figures in converging or diverging angle fittingsfor fixed ducting or opposed blade dampers. Otherwise, changing valvecoefficients (10) are precisely tracked and pinpointed by degree openingor effective radian angle (5) as shown on the quadrant chart example(FIG. 11) for the terminal device and its constant (11). In electricalsignal modulation, this chart simply spans 360 degrees and two or moreOperating Points are in play, such as with total system parameters (23,24) for a moving signal or waveform.

In prior use, certain physical laws known as affinity relationships wereemployed to estimate the performance of such fluid systems through anextrapolation (educated guess) as to how the actual system may performunder given conditions (FIG. 10). These, however, were simplyprojections based on presumptive logic and guesswork. The describedmethod takes appropriate measures using interpolated data, deducting thesolution from three or more known and firmly established verificationpoints.

By virtue of pure logic, one novelty of the described technology is thatit need never rely on any extrapolation (educated guess) to determinetrue performance characteristics. The procedure will always conform aprecise deduction from BHP or Total KW calculating steps, as theseparallel Total Pressure and its subsequent conversion into VelocityPressure (Vp) and Static Pressure (SP). This offers the basis of a newform of logic gate for fluid-mechanical systems. It also proposes acomputer operating system for virtual and real physical environmentswhere in place of the “cursor”, a point or points of operation areinterpolated by the processor for the appropriate physical actions,whether scalar or vector in nature.

In current systems, so-called “floating” data points tend to be viewedindependently and compound errors result. Current systems utilizeextrapolative performance projections based namely on Static Pressuresensing with sensors also placed in a questionable context, both up anddownstream of dampering or other variables where correct interpretationis rendered inaccurate and unreliable. Movers and valves can only “hunt”for an obscure range or point of operation from conflicting sensor dataas pressure increases can be as equally attributed to block-tight StaticPressure as they can be to fan power being applied effectively. Thisalso easily confuses the blower because most typical centrifugal fansexhibit the same Static Pressure characteristics despite a vastlydifferent flow rate, at approximately their 30% and 70% points of “WideOpen Flow”, known as their surge points. This is especially pronouncedon the low and high end of the curve where the motor's Power Factor isalso not made use of appropriately. This problem explains “blowersurge”, however, the method algorithm also addresses the phenomenonknown as “system surge”, another adversity in fluid systems.

Though the described Operating Point may be placed in any desired fieldfor efficiency or effectiveness, its prime function also accounts for“Fan Horsepower”, “Air Horsepower”, and “Water Horsepower”, additionalforms of BHP denomination, as well as overall “Mechanical Efficiency”where the unit “driver” and “driven” components are in play. This coversany internal drive losses as well as polytropic effects imposed by thecompressible or incompressible state of fluids.

Efficiency is usually the biggest questions mark in such systems,because it is often obtained from a manufacturer's said tag HP (not BHP)or some previous estimation. Mechanically, this component may also bederived from sensor data where BHP is first determined by alternatemeans such as on a torque gauge along with RPM readings; Torque (lb-ft)X RPM/5252. Mechanical output, however, is appropriately determined anddistributed via the sensing apparatus from Total Pressure conversion asproduced by system load under specific variation. ME (MechanicalEfficiency)=AHP (Air Horsepower/BHP; or WHP (Water Horsepower)/BHP; anyfluid stream power/BHP.

Electrically, a direct Power Factor reading (KW/KVA) or P/S can be takenand remaining electrical unknowns are derived from the power triangleconsisting of P, S, and Q (True Power, Apparent Power, and ReactivePower, respectively). The Pythagorean Theorem follows in thisrelationship where Q (reactive)=SQ. RT. S SQ.−P SQ. and so forth.Additionally, comparative data may be derived from Mechanical Efficiencyto assess the electrical-mechanical translation of these components.

Power Factor is central in assessing electrical power output, along withelectrical efficiency—power available for useful work, as opposed to KWinput. But between power draw from the mover and translations of TotalPressure, the actual unit efficiency is accurately determined in a realsystem as opposed to a “proposed” efficiency, whether mechanical orelectrical. Also, BHP may be derived from input KW (voltage and amperagereadings) where only the Power Factor is known, this determined bydirect Power Factor reading, input KW/KVA, or other means. KWoutput=IXEXPF/1000 (single phase power); or IXEXPFX1.732/1000 (threephase power). Once true power output is assessed, then electricalEfficiency=746XBHP/EXIXPF (single phase power); or 746XBHPXEXIXPFX1.732(three phase power). If this were “proposed” efficiency, then BHP wouldbe tag or manufacturer “HP” and estimated “PF”.

Velocity reading as per pitot tube multi-point traverse is deemed amongthe most accurate datum points with its closed-loop sensing, second toBHP. Static reading is deemed the least accurate. Additionally, StaticPressures are prone to atmospheric differences inside of a buildingenvelope (highly significant at 14.747 PSI) when used out of context ofthese other crucial data verification points. This discrepancy in itselfcan equal the addition or absence of a large capacity mover. Thisunacceptable margin for error can easily be breached if such pressuresare not viewed as “absolutes”, taking an atmospheric reference intoaccount at both manufacturing stages and at final testing stages of an“as-built” system.

Under VAV operation, the method algorithm performed by the saidapparatus establishes a set criteria for the “System Diversity”amount—the specific energy saved—and the control system may itself “mapout” this diversity through its own default operation setting as mosteffective for an existing or “known” system. Solved unknowns areextracted from precisely coordinated relationships using the saidverification data points. The diversity manifests itself in minimumrequirements for all loading demands and minimum valve positioning in areal system.

The Diversity is a valuable amount of the distribution system that canbe set aside when not in use, a margin for saving energy, when portionsof the mover and system are not in full demand instantaneously or, inother words, “not instant.” Current methods of “instant” reading orsampling flow and pressure data, however, cannot keep up with thesecomplex changes, namely due to a problem known as “flow-pressurestability” and other analog-digital control limitations. These can beviewed on a power triangle signal graph. Logging these clocked leadingand lagging “trends”, this adverse effect becomes increasingly apparenton the fluid control side of the equation and then reverberates througha cascading effect through all high and low voltage electrical systems,including microprocessors as well. The described technology offers asolution to this inherent problem on a fluid-mechanical, thermal, andelectrical level.

Because critical areas of a fluid system change under modulation, themode of operation continually adjusts the total circuit path and itsdemands on the mover, which fall into play precisely where needed at anygiven time or constant as the ordinate, abscissa, and “sigma” sensorvalues would indicate (FIG. 13). This is especially crucial in airsystems due to their changing flow coefficients with adverse effectsimposed by damper modulation and damper angle adjustment. Due tolimitations of current systems, valves operate within only a small partof their usable range. Utilizing the specified method algorithm andprescribed apparatus, the variable mover and plurality of valves areplaced in the broadest and most effective range possible within thegiven system.

Aside from the VAV Mode, other specified modes, notably Test Mode,Balance Mode, and Smoke Mode, simply use similar terminal device or maindampering techniques to effect other actions. Lab Test, then BalanceModes would apply from initial lab testing stages through to start-up,troubleshoot and calibration of the system as needed. “WOAF” (Wide OpenAir Flow) originates from the nascent stage, where initial data pointsare first established and recorded in the database provided, or derivedfrom some other accepted source. Smoke Mode is triggered by a conditionin a built-up system of fire smoke evacuation in which all valvevariables are at wide open parameters, namely 100% O/A (Outdoor Air)injection, but fully closed R/A (Return Air). As added measures, theremaining functions deal with eliminating leakage and “System Effect”factors through isolated sensing and dampering techniques as specified.

The Expansion-Compression Cycle

The fluid metering and control unit also applies optimal functioning inrefrigeration systems where the DX expansion-compression cycle is used.Here, the terminal device or heat exchanger may be a vessel ofcompression or a vessel of expansion. This subject matter pertains tocompressible fluids or gases where a polytropic process is assumed alongwith air-fluid changes occurring above atmosphere as well as thosebelow, such as in vacuuming (suction) applications. Critical mass flowrate and timing through the heat exchange refrigerant coil, expansionvalve, water coil, or other HX medium are also precisely controlled thisway through functions pertaining to heat exchange of diverse fluidscrossing paths with one another in different configurations,counter-flow being the most effective.

In summary, the path of critical mass flow in variable systems isprecisely manipulated and tracked by the “Point of Operation” referencepoint, expressed as either a scalar function or a vector function. Thiscomplex coefficient maintains an adequate flow-volume-pressurerelationship in the whole system, totally and terminally, thussatisfying the need for system diversity on a fluid-mechanical andthermal dynamic level.

Moreover, the key utility of this patent provides the means of “tuning”most all machines and mechanical devices for operating at their optimallevel of power and efficiency at any given time or constant. Thisincludes fully articulated operation through all varying volumes,densities, variable geometries, and, ultimately, critical mass flowrates at their maximum possible effectiveness.

BRIEF SUMMARY OF THE INVENTION

The method and apparatus offers a complete air-fluid distribution,control, and management system beginning with the primary mover of suchsystem and extending through to all components, branches, sub-branches,and terminal outlets/inlets required for air-fluid delivery of thatsystem. The key basis for its operation is its fully articulated andcomprehensive flow-pressure analysis, namely a breakdown of Total Powerin the form of Total Pressure, Static Pressure, and Velocity Pressure,where in previous automated systems and design methods the velocitygradient was largely ignored and temperature-based systems more thefocus. Considering thermal measurements, the method and apparatus alsomonitors heat flow at primary and terminal heat exchangers, and may doso in coordination with flow-pressure gradients.

The method and apparatus utilizes the three key pressure gradients toestablish an exacting degree of influence that each carries throughoutthe system by determining a percentage of content of Total Pressure and,as a result, is able to diagnose specific problems and present solutionsto those problems in an innovative and complete way as never before.

When designing an air-fluid distribution system, the method andapparatus evaluates Total Gains and Losses, then Specific Gains andLosses occurring throughout every section of a new or existing system.This procedure begins with the primary mover and extends to allcomponents of the system, such as any terminal flow control device ineither series or parallel operation, or in any form, number, orcombination.

The method and apparatus can also make precise assessments as to whetherequipment sizing and specifications will adequately and efficientlyserve said system, beginning with the primary mover and its total powerinput/output, down to every terminal branch or component of the systemand its repercussive impact on the whole.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 depicts a schematic main overview of the method and apparatus asit might appear on a simplified HVAC distribution system with oneprimary mover, one terminal device, two heat exchange terminals, andreturn air/supply air ductwork fitted to a typically housed draw-throughunit.

FIG. 2 depicts an “old school” rendition of how Mover Total Pressure ismeasured with two total impact tubes and a U-tube manometer.

FIG. 2A depicts an “old school” rendition of how Mover Total Pressure ismeasured with a) a static probe and b) an impact tube, and U-tubemanometer.

FIG. 2B depicts an “old school” rendition of how Mover Velocity Pressureis measured with a pitot tube connected to U-tube manometer.

FIG. 3 shows a schematic illustration profiling a typical draw-throughunit and its internal components with a breakdown of TSP (Total StaticPressure,) TESP (Total External Static Pressure,) Filter pressure drop,and Coil pressure drop.

FIG. 4 depicts an enlarged view of a mixing box with mixed airstreamsand damper control in Normal Mode Operation

FIG. 4A depicts the same mixing box with 100% OA (Outdoor Air) and 0% RA(Return Air) as seen in Smoke Mode operation, along with a Total SystemCurve window reflecting SP, Vp, TP changes and OP (Operating Point)deviation.

FIG. 5 depicts traditional fan performance curves of four differenttypes.

FIG. 6 depicts a typical “wide open” curve for an FC (Forward Curved)fan with a suggested system operating point shown.

FIG. 6A depicts a mover “wide open” curve with three part pressureoption displayed as made possible by said method and apparatus.

FIG. 7 juxtaposes a known mover “wide open” curve alone and same with anunknown system attached.

FIG. 7A juxtaposes a known terminal or in-line device “wide open” curvealone and same with an unknown sub-system attached.

FIG. 8 depicts a typical Air-to-Water terminal heat exchange device withsensor placement and configuration.

FIG. 8A depicts a Water-to-Water terminal heat exchange device withsensor placement.

FIG. 8B depicts an Air-to-Air terminal heat exchange device with sensorplacement.

FIG. 9 illustrates the main panel display of the performance curvesgoverning the entire air-fluid distribution system with all componentsshown as related to flow-volume and pressure relationships. Thisincludes the Total System Curve and main cross hair operating point, theTerminal Branch system (or Sub-system) curve and operating point, movercurves and given constants, and SP/Vp breakdown by percentage, ratio,and visual display indicators. A vectorial display compass is also shownas an image overlay option.

FIG. 9A is a blow-up view of the SP and Vp curves individually, alongwith the mover/system constants they are plotted against. Also shown arevariable X % and Y % content, these comprising Z (or Total Pressure.)

FIG. 9B is a blow-up view of the Total System Curve plotted with TP(Total Pressure) sensor logic against the primary mover. Total system OPalso shown in cross hairs.

FIG. 9C illustrates a detail view of the Terminal Branch (or Sub-System)main Total Pressure curve plotted against the terminal device flowconstant curve. Terminal Branch Operating Point shown in cross hairs.Also shown to the left of curve display are indexed options forselecting a TBSP or TBVp (Terminal Branch Static Pressure or TerminalBranch Velocity Pressure) curve breakdown.

FIG. 10 displays the three part system curves as they might be viewedindependently with x/y coordinates and affinity law mapping of the curvesegment unknowns from a known starting point established through sensorlogic or reference materials.

FIG. 11 illustrates a complete “wide open” portrait of a modulatingterminal device (or valvic device) through its full range of motion,along with an index of options (to the left) notating TP, Vp, and Sp forarbitrary setting. The suggested default or design operating parametersare shaded for the selected operating range. A suggested default ordesign-specified terminal branch or sub-system OP is also shown at 45degrees (50% open.) The index also includes a dial setting for alteringthe TD's characteristics under any and all conditions with TP, Vp, or SPbeing switchable and variable through any percentage or degree ofclosure.

FIG. 12 depicts curve riding and OP deviation when mover changes occurand, conversely,

FIG. 12A depicts curve riding and OP deviation when system (orsub-system) changes occur.

FIG. 13 is a sensor grid schematic of the sensor logic employed by themethod and apparatus, including cross-sectional areas for sensorarrangement. The symbols are familiar as flow monitor stations, thoughare referred to in this specification by solid, broken, anddotted-broken lines to indicate TP, SP, and Vp, respectively.

FIG. 14 depicts Primary Mover sensor logic as employed by the method andapparatus to measure Mover TP.

FIG. 14A depicts Primary Mover sensor logic as employed by the methodand apparatus to measure Mover SP with an optional attachment (sensorgrid) for packaged, housed, or otherwise fitted movers under field orexisting conditions.

FIG. 14B depicts Primary Mover sensor logic as employed by the methodand apparatus to measure Mover Vp with an optional attachment (sensorgrid) for packaged, housed, or otherwise fitted movers under field orexisting conditions.

FIG. 14C depicts Mover sensor logic and augmented SP, as demonstrated bySeries Operation. Optional sensor grid fitting also shown.

FIG. 14D depicts Mover sensor logic and augmented Vp, as demonstrated byParallel Operation. Optional sensor grid fitting also shown.

FIG. 15 depicts Terminal or In-line device sensor logic as employed bythe method and apparatus to measure such a device's TP.

FIG. 15A depicts Terminal or In-line device sensor logic as employed bythe method and apparatus to measure such a device's SP. Optional sensorgrid fitting also shown.

FIG. 15B depicts Terminal or In-line device sensor logic as employed bythe method and apparatus to measure Terminal Device Vp. Optional sensorgrid fitting also shown.

FIG. 15C depicts Terminal or In-line device sensor logic with asecondary mover in Series Operation and the resulting increase in SP.

FIG. 15D depicts Terminal or In-line device sensor logic with asecondary mover in Parallel Operation and the resulting increase in Vp.

FIG. 16 demonstrates an embodiment utilizing dual damper and motor speedcontrol in Series Operation in a system with long runs and minimalfittings.

FIG. 16A demonstrates an embodiment utilizing dual damper and motorspeed control in Parallel Operation in a system with excessive bends andfittings.

FIG. 17 demonstrates one version of a leakage tester embodiment using amover, terminal control device (auto damper control,) and a capped mainsection of duct. SP and Vp curve level offs are shown as indicators.

FIG. 17A demonstrates another version of a leakage tester embodimentusing a mover, terminal control device (auto damper control,) and a newor existing system that has already been fitted. Leakage represented byVp deviations (increases) from firmly established OP's.

FIG. 18 depicts an additional embodiment used for determining the volumeand overall characteristics of a given vessel or enclosure. Curvesdisplayed with cut offs and level offs, along with percentages of Vp andSP content. Vp cut off occurs where SP reaches 100% of mover's totalstatic power, less total static drop of the terminal device, less any Vpdeemed leakage at level off.

FIG. 19 shows a detail view of the Vectorial display compass crosshairs, which illustrate all OP changes in any given direction, in anygiven context of mover and system or sub-system. The display acts as akind of cursor to all effective system changes as they happen or afterthey occur within a given time frame. It may also be “locked in” at aspecified operating point to display all related changes of a real ordesigned system in its entirety, prior to anything being built.

FIG. 19A shows a Total to Sub-System Vectorial Analysis where acorrelative relationship may be drawn between these or any other systemcomponents generating such a curve or movement vector. This framework istransposed on the main curve display screens, or may be viewedindependently to show a “bare bones” rendition of any and all effectivechanges as mover-system adjustments are made arbitrarily orautomatically through default operation.

FIG. 20 is a basic depiction of System Diversity, a concept referred tothroughout the description to illustrate a variable distributionsystem's tempering of total mover capacity to required system, and nomore, no less, to accommodate load where and when needed. This functionsas a supporting concept for said method and apparatus and additionalclaims presented.

FIG. 21 depicts the Main Menu display as it might appear to offer aselection of key options, namely the type of distribution system, priorto proceeding to system start.

FIG. 22 outlines a basic air system flow chart with all keyconsiderations for such a system, establishing a standard forprioritization before proceeding to each subsequent step or mode ofsystem operation. Any additional considerations or requirements are metthrough an upgradeable, searchable database that covers, but is notlimited to, general equipment selection, movers, terminal devices, heatexchangers, fittings, and troubleshoot possibilities.

FIG. 22A outlines a basic hydronics system flow chart with all keyconsiderations for such a system, establishing a standard forprioritization before proceeding to each subsequent step or mode ofsystem operation. Any additional considerations or requirements are metthrough an upgradeable, searchable database that covers, but is notlimited to, general equipment selection, movers, terminal devices, heatexchangers, fittings, and troubleshoot possibilities.

FIG. 22B outlines a basic terminal device system flow chart with all keyconsiderations for such a system, establishing a standard forprioritization before proceeding to each subsequent step or mode ofsystem operation. Any additional considerations or requirements are metthrough an upgradeable, searchable database that covers, but is notlimited to, general equipment selection, movers, terminal devices, heatexchangers, fittings, and troubleshoot possibilities.

FIG. 22C consists of a Possibilities Display Menu for Air systems,including but not limited to any and all known possibilities for adversemover-system performance in whole or part. This also refers to anupgradeable, searchable main database encompassing every availablecomponent of such a system, offering output such as motor/driverecommendations, or final “as-built” retrofit options.

FIG. 22D consists of a Possibilities Display Menu for Hydronics systems,including but not limited to any and all known possibilities for adversemover-system performance in whole or part. This also refers to anupgradeable, searchable main database encompassing every availablecomponent of such a system, offering output such as motor/driverecommendations, or final “as-built” retrofit options.

FIG. 23 illustrates the final marginal boundaries for constant andvariable system performance with a final pressure/head constant, low tohigh.

DETAILED DESCRIPTION OF THE INVENTION

The process begins with the primary mover 1, which in this example shallbe an HVAC unit and system equipped with some form of blower or fan tocreate air movement and generate system pressure.

The prime concepts at work here will be TP (Total Pressure,) theintended meaning conveyed to be understood as “all impact forces,”static and velocity combined. SP (Static Pressure,) and Vp (VelocityPressure.) TP=SP+Vp. It is understood that the latter two are mutuallyconvertible throughout a given system and that TP decreases in thedirection of flow.

As mentioned previously, unlike the traditional concept of TP, most fancurves indicate Total Static Pressures for viewing fan and systemperformance curves due to current packaged systems. A notation will bemade where applicable.

Initial Operating Point for System Total and Primary Mover

The standard procedure after “as-built” system start-up occurs beginswith the following: A design system curve 5 operating point 10 based onfan selection will be displayed as intended for normal operation.Following this, the method and apparatus will take all necessaryreadings with its own sensors 13, 14, 15 and controls arranged accordingto the described method to establish an actual operating point 10. FIG.9

The conditions will be with completed, connected ductwork and alldampers/valves “wide open” or indexed to maximum positions with nounintended obstruction, under full load conditions, less diversity ifone is present.

Dispersed throughout the system and not concentrated in any areas, thenumber of variable air volume terminals, automated dampers or valveswhose terminal branches equal this diversity amount 22 shall be closedor placed in their minimum positions to accurately represent the systemcurve the mover is actually sized for, this amount being less diversity.“Terminal branch” shall be defined as a total of given individualterminal outlets/inlets and, thus, a subtotal of the whole system.

The above point often misunderstood, the primary mover's capacity shouldbe sized exactly for the amount of “system” 5 it is to be applied to, nomore, no less. Mover 11 and system 5 are plotted against each otherbased on this premise being correctly established. The diversity 22 isan amount added to this that the system 5 can cope with when other partsare not in need or demand. This is why we negate that portion of thesystem when establishing a curve. Otherwise, the curve is misrepresentedwith more dimensional system 5 (length, surface area, etc.,) and, hence,a substantial deviation from the intended operating point 10 is depicted6. FIG. 12, 12A. Also, the whole point of a diversity factor 22 isdefeated if not correctly applied. Another key advantage of the saidmethod and apparatus is its allowance of considerably higherdiversities, as well as its ability to map them within a given system 5.These functions result from traversing the varying landscape the system5 as a whole is comprised of. (See section on system diversity andrelated claims.)

After the above conditions are firmly established, the process resumesas follows:

-   -   1) A fan rpm reading may be taken with a photoelectric        tachometer installed inside the blower housing and aimed at a        reflective marker on the fan wheel. Alternatively, the FRPM        reading may be taken by other means via motor control 7, etc.        The motor tag data, namely Efficiency, Power Factor, HP, Volts,        and Amps, will be entered as known inputs to determine 2) BHP        (Brake horsepower,) through the equation: V×A×PF×EFF×1.73 (3        phase)/746. The factor of 1.73 is negated for single-phase        systems. 3) A Total Static Pressure will be taken with those        static sensors correctly placed laterally at the blower cabinet,        facing the inlet, and at the surface discharge of the blower;        this to concur with manufacturer data and terms set forth        previously. The appropriately situated flow monitor station 2        will accurately establish this static reading at its sensing        station, along with 4) a Total Fan CFM, all at a location where        there is laminar (uniform) flow. FIG. 1        Note: The above sensing arrangement example conforms to current        equipment performance data, based on Total Static Pressure, as        described in Background. This is used for clarity, though all        added advances of the method and apparatus, including the        three-part curve analysis, are detailed subsequently.

Based on the above fundamental data, the system will attempt toestablish at least three verification points that agree with projectedsystem characteristics as specified. Mover performance is anticipated tofollow the affinity laws and, if not exactly, conform to or closelyparallel intended design curves, wherever their placement may be. If thefourth item deviates greatly from this framework of known characteristicoperation and principles, some other unknown variable is at work in thesystem. The user interface system will display this as an error messageand request that the problem be corrected before proceeding.

Only certain, known occurrences may distort the system curve 5 or plotone falsely. Among these known from prior testing and experience are thefollowing: System Effect losses, as previously noted. This is acondition that will be recognized by an experienced balancer or engineerthrough visual inspection, followed by calculations to determine theextent of this effect, as it cannot be measured in the field withinstruments or current automated control systems. However, the SystemEffect may be determined, or moreover, ruled out, with said method andapparatus as the description supports this added claim, particularly dueto the Vp gradient in mover evaluation.

The following known phenomena could also wrongly portray the systemcurve: two typical blowers operating in parallel and separately ductedto one another, load shifting with one another, a little known factwhich has confused system and fan curve performance in the past;another, substantial leakage or bypassed flow within packaged unithousings, this being the minor concern. In any case, both are highlyunlikely and a greater concern with outdated existing systems quicklybeing replaced. Another confusing factor may be poor instrument or flowsensor calibration (instrument inaccuracy,) leakage within near-obsoletedual duct (dual deck systems,) significant leakage in general, and otheroddities that may be prevented with proper care, maintenance, andstandard procedure as set forth by the certified balancing process ofsuch systems.

A certified balancing firm ascertains flow-pressure rates with their ownregularly calibrated instrumentation and this sets the record inagreement with properly installed flow-pressure sensors and hardware atthe outset of a project. The described method and apparatus will be inagreement with this standard testing procedure. Any more obviousdiscrepancies such as motor belt-drive adjustment, alignment, motorpower, slippage, or unit sizing will become immediately apparent simplythrough following these processes, one way or another, whether by fieldinspection or automated feedback from the method and apparatus.

This is where the role of a Testing and Balancing Supervisor is central.In conducting their own independent testing, the balancing agency willfirst confirm the collected field data with timely calibratedinstrumentation. This will correct any calibration problems or moreobvious logistical problems stemming from installation of the system,and most commonly resulting from simple equipment scheduling conflicts.After a certified balancing firm has followed their standard procedurecorrectly, all items affecting these systems will be covered as theyfollow the initial procedures outlined here.

The flow monitor station 2 will also supply additional data underlyingthe theme of the isolated velocity gradient and static gradient asseparate analytical elements, here comprising the total pressure andeffective power which will be made available to the remainder of thesystem downstream. Aside from establishing total capacity (CFM) andTotal Static Pressure, the station will also perform these functions asillustrated in FIGS. 9, 9A, and 9B. Additionally, the static pressureprofile, as previously described, will be displayed with the overallsystem diagram as shown in FIGS. 1 and 3.

This will permit further, more detailed analysis of the air streamacross its full path of flow from suction to discharge of theair-handling unit itself, namely to determine any deficiencies which maybe caused by localized effects, such as filter loading or coil finclogging and other such obstacles within the housing which may causeunusually high losses of a dynamic and/or static nature. When theprofile is in question, it is understood that this be an SP (StaticPressure) profile, since using sensors only of this type are practicalconsidering the logistics of unit housing. This may only require asingle point reading in a normal enclosure, though an equal area averagewill be recommended when used in housings with unusual internalcomponents that may created turbulence or eddy currents with airpockets.

If determining dynamic losses within a mover housing is desired,however, this may offer a lab use application, namely for themanufacturer to catalogue known dynamic losses at given pressure dropsunder pre-determined lab conditions. Note that static pressure dropsalone are not indicative of flow rates through a known device (active orpassive) in an unknown system, though this is one of many problemssolved with the said method and apparatus, as set forth. The method andapparatus may also deduce that any static gain relative to total lossesis indicative of a dynamic loss, and assess its specific content:TP−SP=Vp; % Vp of TP.

A Distinction of Uses: Lab Use versus Field Use

Lab Use: Wide Open Curve

To begin with, a “wide open” test can be conducted under defined labconditions. Note the typical “wide open” fan curve in FIG. 6, and theadded options presented in FIG. 6A

This utility is the one that will use a three-fold method of assessingmover characteristics for tabulation or cataloguing purposes. Theprocedure will employ the base concepts of Fan Total, Fan Total Static,and Fan Velocity Pressures as illustrated in FIGS. 14, 14A, and 14B.Also refer to the main sensor logic layout in FIG. 13.

This arrangement will utilize three distinct sensor grids: 1) a totalimpact grid 13, 2) a static pressure grid 14, 3) a velocity pressuregrid 15, this simply being a differential of the previous two averagedsignals, though a separate grid avoids any additional losses caused byT-fittings or other “tap-ins” from the other two grids that may distortthe signal and produce an unacceptable standard of testing. Obviously,this lab use variation of the method and apparatus is best suited to alab arrangement, where grids (sensing elements) can be removed andinstalled independently for each separate performance curve.

The test conditions must be made relative to atmosphere, and with anyappropriate corrections made for other than standard air (70 F, Cp=0.24,sea level, 29.92 Hg.) Again, Vp is a positive reading taken in a closedsignal loop (High to Low on a micro-manometer,) moving in any direction,but TP and SP are both either positive or negative, and relative to openatmosphere. Therefore, the manometer High or Low connection (dependingon whether the air stream is discharge or suction) is to be taken inlieu of a tainted building envelope.

The mover itself must also be in a location that is in perfect balanceor constant volume neutrality, wherein outdoor air entering a buildingenvelope equals exhausted air. If testing a non-ducted blower inlet, thedischarge is usually ducted to its “100% effective length” to developlaminar flow and some form of static power by way of enclosure on thedischarge side, as suggested by AMCA standards of testing. The describedmethod and apparatus allows for this form or any other form of testing,with or without fittings attached as outlined by current methods. Noteoptional sensor grid arrangements in FIGS. 14A and 14B.

The readings can be made with test instruments, such as micro-manometersin certified calibration or a classic U-tube manometer, which requiresnone.

The arrangement intended for establishing mover characteristics at anypercentage of “wide open” flow will answer the following key questions:

Q: How much of a total impact gain did this unit generate in of itself?Q: How much of the total gain is in the form of SP (Static Pressure?) %Q: How much of the total gain is in the form of Vp (Velocity Pressure?)%

A Vp/SP ratio or SP/Vp ratio may also be expressed as factors: VpFactor. SP Factor. This data can then be used in coefficients andfriction loss tabulation.

The above method and apparatus will provide indispensable engineering or“lab conditions” test data and is not the same as the arrangement in theinstalled version, as it may not be practical to have this three-foldsensor arrangement in a field version, let alone remove or replacesensor grids. For all intents and purposes, the above description isonly necessary to establish comprehensive and official certified datafor a catalogued device. And once this is done, the mover is of knowncharacteristics and its performance can then be accurately predictedwith simplified sensing devices in field use.

Measurements will be taken from inlet to outlet of said mover toillustrate the gain occurring during the air-fluid's path before andafter encountering the mover at its full speed of rotation, namelydriven RPM, where there is a drive involved 7, as opposed to directdrive, or other rotational speed as arbitrarily set. This will be usefulfor design considerations among many other uses. Following this initialorientation, a three-part performance curve comprised of TP, SP, and Vpwill be plotted across the full range of rotation (fan RPM,) whetherthis is achieved by means of drive (pulley) adjustment, VFD (VariableFrequency Drive,) or any form of variable/multi-speed control 7.

The “percentages of content,” a term traditionally used in reference tomixed airstreams, will be determined: SP and Vp of TP. Namely, theVelocity Factor or Gradient of this content will be the keyconsideration in high velocity applications or systems and what remainsis in the form of static pressure, or Static Factor. The latter wouldapply to high pressure-type applications and systems. Useful ratios willbe noted, from percent closure to maximum/minimum flow capacity. TotalGains and Specific Gains, changes, losses, valuable characteristics canbe viewed 6 entirely across the plotted full range of motion (fan speedor % of wide open flow,) with the ability to “interlock” all desiredcharacteristics and constants for viewing consideration for theirultimate effect on the system whole.

The main panel display and user interface 6, made up of key components,may produce real or virtual testing by locking in the desiredcharacteristics and obtaining all needed data required to build theideal system 5, down to the very drive and pulley sizing required to doso. This process may begin as early as in the design stage all the waythrough to “as-built” status.

Alternatively, traditional blower characteristic curves, such as thoseshown in FIG. 5, may also be plotted, though these may be found to beless useful, if not irrelevant within the context of a given real andarticulated system connected thereto owed to current limitations ofstock sizing and the “static” projection of such a system's “would be”performance based only on percentage of some damper closure. The keyelements will be displayed 6, however, with the TP, SP, Vp gradientcurves opted for, along with BHP curves plotted on the right side of thecurve display, noting that these vary greatly with various mover 1types. Most notably, centrifugal-type movers experience their lowest BHPat full closure while, conversely, axial or positive displacement moversexperience their highest BHP at full closure or “no flow” shut-off head.This latter point again emphasizes that any obstruction to the velocitygradient or its proponents within a system is counter-productive. Asdescribed, BHP is plotted from electrical data obtained from the motor 7that powers the mover 1, namely its Voltage, Amperage, Power Factor, andEfficiency. This is plotted along with all other gradients across thefull range of closure and mover rotation. FIG. 6, 6A.

In summary, the described method and apparatus will establish acomprehensive evaluation of all mover 1 characteristics, its values orlack thereof, in full scope of operation, within or without the contextof a connected system 5. This, in turn, will establish the best suitedoperating range, or point of greatest SP/Vp throughput gain for thegiven mover. Most movers have a “no select” performance zone, roughlydefined as anywhere below 40% of wide open flow, where flowcharacteristics are deemed unpredictable enough to preclude reliableequipment selection below this point. Wide Open Fan Curves will clearlydelineate this boundary in cataloguing.

The method and apparatus can also be employed to determine which system5 or type of system (vessel or conduit of air-fluid delivery) is bestsuited to that specific type of mover 1 for the desired application bymating the given mover to its ideal system in every measurable degree.This automated pairing of mover to system, and vice versa, along withbeing a mover-system design and selection tool, presents additionalclaims.

Again, alternate functions may be served with or without a“blow-through” or “draw-through” system attached. Also, it should benoted that a blower alone is not a packaged system, but merely anatmosphere exposed “wide open” system that is tested under agreed uponstandards, such as those established by AMCA. The Wide Open Curve willshow the recommended operating percentage of closure, although theoptional sensor arrangements shown in FIGS. 14A and 14B may be used totest an already packaged or fitted unit within or without a completesystem 5.

This condition becomes understood when a packaged system is placed inthe typical fan housing cabinet, along with any throttling that occursbeyond that point by means of main dampers, vortex blades, mixing boxes,etc. Again, the effect of atmospheric pressure bearing down on the inlet(+14.696 PSIA absolute,) such as would be created under wide opentesting of a mover, will not be the same once enclosed and operatingwithin a building envelope, especially where an open plenum (non-ducted)return is involved. Building pressurization will compromise the testarea. These or any such biased conditions should be noted, controlled,and parlayed with consistency through to the mover's final packaging andapplication in the field.

Finally, after the mover's “wide open” characteristics are evaluatedusing the described method and apparatus, the process may be continuedthrough to a packaged system, where the TP curve is replaced by TSP orTESP (refer to FIG. 1 and FIG. 3.) in any other form, delineation, orcombination.

Field Use

Under field conditions testing of an “as-built” system, best resultswill be achieved if the said method and apparatus was used fromorigination. If this is not the case, “aftermarket” components may beinstalled as a retrofitted option. For example, necessary key systemcomponents may be fitted with some or all of the sensor grids 13, 14, 15or equivalent inlet/outlet-only sensing arrangements, along with theuser interface, which may be as large as an entire building managementsystem 6, or as small as a localized push-button display panel 6.

In any case, utilizing the method and apparatus according tospecifications will produce far superior results than traditionalmethods of sensor control currently in use, particularly with propercalibration using the same procedures outlined here.

Again, the TSP, SP profile, and resulting TESP will be the main concernsin field use with an existing system. First, maximum load conditions asdescribed in “Background” are clearly established. The initial start-upprocedure then follows, as outlined in the section: “Initial OperatingPoint of System Total and Primary Mover”

Subsequently, many unknowns may be determined. For example, a knownmover 1 with an unknown system 5 attached may be evaluated, or viceversa. Once mover characteristics 11 alone are established, then thetrue operating point 10 of an unknown system connected to that mover mayalso be established. FIG. 7. This added function presents additionalclaims on the method and apparatus.

Hydronic and Fluid Pumping Variations

Unlike air and gas systems, hydronics or heavy fluid systems will havekey differences as follows. The primary concerns will be TDH (TotalDynamic Head), NPSH (Net Positive Suction Head), suction lift in opensystems, maintaining a water level datum line in open system basins, andhaving adequate fluid in either type of system to reach the highestpoint of the given system without any entrained air. The key breakdownof hydronics terms: dynamic heads (velocity head pressures—dynamicdischarge and dynamic suction head) or static heads (weight or pull of alength of water column in the form of either static suction head, staticsuction lift in open systems, or static discharge head.) The otherdetermining factor in hydronics pump sizing is piping friction losses.

Open and Closed Systems

Total Dynamic Head is the fluid equivalent of Total Static Pressure inmodern blower performance curves and for all intents and purposesestablishes total power generated by the primary mover 1. It is measuredas a differential of suction and discharge (dynamic) forces produced bythe working pump, preferably by one differential gauge connected to doso. The measuring unit is Ft/HD (Feet of Head) for pumps and terminal,in-line units, and inches of water for calibrated balancing valves, or“circuit setters.” PSI gauges are often connected anywhere taps or gaugecocks are located in the system and are then converted to Feet of Waterunits as required for monitoring basic pressure drops at critical pointsof the system, such as makeup water or bypass junctures.

Open systems require more critical monitoring, particularly those havingelevated pump centerlines and, hence, static suction lift due toelevation. In hydronics mover selection, suction lift is added in totalpumping head required in this type of system, including piping frictionlosses and static discharge head. This is done rather than figuring adifference of the two heads as in systems having both sides, supply andreturn, elevated above the pump centerline, open or closed inclusive. Inthe latter case, the elevated piping systems have the closed, connectedwater columns bearing down upon them and these forces are hence,negated, from the pumping total power, plus piping friction losses.

Unlike raised piping systems, having a suction head makes it moredifficult to maintain an adequate Net Positive Suction Head in opensystems. Maintaining water levels at cooling tower basins are also aprime concern with open systems, as if they drop, vortexing can occur atthe basin and possibly cavitate the suction side of the tower's pumpwith entrained air. These are not concerns with closed systems. Somecommon problems they do share, however, are the following: airentrainment. Having air vented from the systems at crucial points toprevent damage due to entrained air entering the pump casing iscritical. Having an adequate water level in the whole system, asdetermined by a “pump-off” PSI (converted to feet) as a directindication of actual height from the pump centerline to the highestterminal point of the system. The expansion tank or compression tank isanother key component that handles any volumetric changes due totemperature/density and air entrainment that might damage the system aswell. The tank generally needs protection against a condition known as“water logging” when managing air entrainment and volumetric changes inthe system.

Aside from these variations, the lab and field condition testingprocedures outlined in air systems apply as well with hydronics or fluidsensing elements using the same basic principles. Dynamic flow orVelocity Head in heavier, less compressible fluids, however, has beenall but negated entirely for practical design considerations (from adesign perspective,) though lighter fluids and mixtures may reap agreater advantage from establishing the velocity gradient, along withthe Static Head (or Pumping Head) content, especially since largedemands are made on brake horsepower and, thus, total power (kilowatts)where high static heads (or pressures) are applied too liberally.Terminal devices, however, in either air or fluid systems, arevelocity-oriented when plotting flow curves and may show more relevancein this area where practical field or lab considerations come into play;the prevalent point here being that neither factor be neglectedthroughout the given system.

As with air movers, high and low-pressure type pumps are available aswell. Low pressure types (positive displacement pumps) are seldom used,centrifugal being the most widely used in most commercial/industrialpumping applications. The former have other specialized uses, such as inscroll or screw-type compressors and engines moving gas or other lightfluid mixtures. In this context, however, positive displacement pumpspresent problems to hydronics systems, which are inherentlypressure-oriented. These pumps are pressure constant and cannot dealwith sudden or extreme pressure changes, like being throttled at theirdischarge or suction side, or having automatic two-way valves in asystem close down on low demand. They can be seriously damaged this way,and when they are used, many employ a differential bypass sensor tocounter this effect, directly bypassing flow from inlet to outlet of thepump. They generally produce a steep performance curve, while flattercurved pumps (typically centrifugal) are desirable for most applicationswhere pressure drops are to be kept relatively equal at all pipingloops, particularly around the equipment room, where heat exchangers,the expansion tank, and other key components of the system are located.Differential sensors (velocity oriented) are also used in normalhydronics systems to maintain constant flow through the pump,chiller/boiler (heat exchanger,) and other key equipment while pipingsub-circuits fluctuate in their own pressure drops under the varyingconditions of automatic control.

After all entrained air has been removed and all strainers cleaned tobring the system to normal functioning status through normal start-up byan installing contractor, the procedure for establishing performancecharacteristics is begun. This parallels the blower's sequence of stepsand the testing and balancing procedure therewith, with the keydifferences illustrated in FIG. 22A, a hydronics system flow chart.

The pumping affinity laws are basically the same for head (pressure)flow and BHP relationships, the major difference being that flow andpressure increase with an increase in impeller diameter, directly inrelation to flow and squared to pressure ratios; whereas fan rpm(rotation) 11 is the key difference with air systems, though driverpulley adjustments parallel this as well: an increase in sheave size(pitch diameter) equals direct increase in flow by increasing fan RPM11.

The other notable difference in a hydronics system is that as TotalDynamic Head (a velocity head) goes down for a given system, flow (GPM)goes up, whereas in a given air system a higher velocity pressure willalways signify higher flow-volume (CFM,) whether at the primary mover orterminal flow device. This hydronics contingent, however, is based onthe context of a given piping system, one that has much less frictionloss than designed for and, thus, more free flow. This is quite commonsince many safety factors are employed in hydronics systems design.

One source of confusion in both systems perhaps stems from equating avelocity head or pressure with a pressure drop, also a differentialmeasurement, often wrongly ascribed as a measurement of velocity. Thismay be delineated from the inlet to the outlet of a terminal or in-linedevice, or the given distance across which force is applied. A flowmetering process may arise from using the known pressure drop of adevice, for example to establish a Cv, though this is not a method ofdetermining any kind of true velocity change the fluid is undergoingaside from a known device in a known context. Therefore, this ideafollows out of contingency, not necessity. And certainly, this is not aVelocity Pressure (Vp) in the true sense, though it has often beenmisconstrued as such in many a practice. Again, the key understandinginvolves which unit of measurement is accepted and agreed upon for agiven, known system whose performance characteristics were establishedbased on those same principles.

Whatever type of mover, air or hydronics, the units and methods ofestablishing, then parlaying their performance are used perhaps becausethey best suit the current packaging and context they are most used in,as explained previously with packaged systems. Also, a mover 1 is anactive device, while a terminal device 3 is a passive device. The activedevice generates continual applied force and the differential is onecreated by the input and output forces of the mover, from rear to front.

The terminal device 3 passively accepts the applied force and onlycreates loss of Total Power in the form of both Static and Velocitypressure, and not in equal measure. Above all, the terminal device'spressure drop alone is not a measure of velocity and static content,though its “total drop” and “specific drop” will be relevant insurmounting its total losses as a passive device. Delineating thismeasure of forces from primary mover 1 to terminal flow devices 3 setsthe framework for determining which movers 1, terminal devices 3, andsystems 5 are best suited for one another and how they react to oneanother.

The method and apparatus for general applications also complements thestandard procedures for those skilled in the art of hydronicsengineering or balancing:

General Use

A performance curve is plotted at “wide open” flow, or with a givenknown or unknown system attached, from zero flow at TDH to full flow atzero head. This also establishes the impeller diameter, assumingequipment selection is consistent with submittal data. The remainingprocedure of said method and apparatus follows the same guidelines forair system movers and terminal devices, with exceptions duly noted inthis specification.

A Closed System

A closed system is less concerned with atmospheric pressure or makeupwater, only that there is an adequate amount to fill the system withoutany entrained air. The TDH is normally a velocity head differential,dynamic discharge head minus dynamic suction head. I.e., nothing isadded to account for static suction lift, as the close-piped returningloop equalizes the forces.

An Open System

A system open to atmosphere must maintain a water basin level at a givendatum line to provide adequate static head and prevent cavitation on thesuction side of the cooling tower pump. In order to do this, makeupwater must be introduced through a regulated valve and flow sensor(Terminal Devices.)

The other key concern with the open system arises if there is suctionstatic head below the pump centerline. This most often requires a muchlarger primary mover because the static suction lift, discharge statichead, plus piping friction losses on both sides are added together,resulting in a much larger, higher pressure-producing pump beingnecessitated. This arrangement is mostly avoided in real systems, thoughlogistically necessary in some cases.

Primary and Terminal Coil Heat Exchange

Heat exchange may be monitored at every juncture in a distributionsystem at which is placed a heat exchanger 8 in some form or another.Regarding air to water exchangers, such as that shown in FIG. 8, heattransfer characteristics may be determined using the followingequations, Q representing heat flow rate in BTUH (British ThermalUnits/Hour):

Qs(sensible)=1.08×CFM×DT(air side dry bulb)

Qt(total)=4.5×CFM×DH(enthalpy differential from air side wet bulb:H1−H2)

QT(total)=500×GPM×DT(water side)

Ql(latent)=Qt−Qs

And for other than standard air and water:

Air or gas: Qt=60×d×CFM×DH(enthalpy diff.−from wet bulb.)

Qs=60×Cp×d×DT(air side−dry bulb in F.)

Water: Qt=60×Cp×d×GPM×DT(water side)

Thermal Fluids: Qt=GPM×SG×500×Cp×DT(fluid side)

Note: Fluid or gas mixtures, such as glycol solution with an arbitrarypercentage of content would have their own flow charts or tables thatprovide correction factors for Cp (specific heat) and d (density) or SG(specific gravity) with the equation above for thermal fluids or aqueoussolutions. These figures would vary based on the temperature of andpercent mixture of the solutions.D=Delta (referring to temperature or enthalpy differential)H=Enthalpy, as read from a psychrometric chart from corresponding wetbulb reading.Qt=Total heat flowQs=Sensible heat flow

SG=Specific Gravity Cp=Specific Heat

Note: Q sensible is used for heating only mode operation and Q total forchilled water/liquid cooling. Latent flow may be used to determine aratio of air moisture content (total/latent) and may be used todetermine grains/lb or lb/lb of moisture on a psychrometric chart ortabulated data with the following equations:

Q=4840×cfm×DW(pounds of moisture)

Q=0.69×cfm×DW(grains of moisture)

Heat exchange effectiveness equations:E (Effectiveness)=actual transfer for the given device/maximum possibletransfer between airstreams

E=Ws(X1=X2)/Wmin(X1−X3)=We(X4−X3)/Wmin(X1−X3)

E=Total heat effectiveness or a breakdown of sensible/latenteffectivenessX=Dry bulb temp, humidity ratio, or enthalpy at the locations indicatedin FIG. 8B, all differences being positive valuesWs=mass flow rate of supply air, pounds of dry air per hourWe=mass flow rate of exhaust air, pounds of dry air per hourWmin=lesser of Ws and WeLeaving supply air condition:

X2=X1−[eWmin/Ws(X1−X3)]

Leaving exhaust air condition:

X4=X3+[eWmin/We(X1−X3)]

It should be noted that maximum effectiveness potential can never bemore than the enthalpy (total heat) differential of the two airstreams.Counter flow heat exchangers have the greatest maximum effectivenesstheoretically approaching 100%. Secondly, Cross Flow exchangers exhibitmaximum effectiveness at mid-range. Lastly, parallel flow heatexchangers are approximately 50% effective and are used more forspecialized purposes, where no other configuration is feasible.

It should be noted that closed pipe loops, or “run-around’ heatexchangers (air-fluid-air) have individual components whoseeffectiveness is combined by factoring. For example, if two devices eachhave an effectiveness of 90%, the two are factored to determine combinedeffectiveness: e.g., 0.90×0.90=0.81 effectiveness (or 81%.)

The described method and apparatus will address the basic key issues ofheat exchange through automated temperature sensing of air or fluidstreams in any form, number, or combination, including but not limitedto the depictions shown in FIG. 8, FIG. 8A, and FIG. 8B. The sensorlogic utilized by the method and apparatus will pertain directly tothermal dynamics and fluid mechanics, namely to exploit the maximumpotential of any given movers 1 and terminal devices 3 under givenconditions. This includes the total and specific fluidic gains/lossesthe components of the distribution system create in of themselves and,above all, these previous elements may be manipulated in cooperationwith one another for maximum heat exchange effectiveness under varyingconditions.

Once establishing maximum effectiveness possible—actual versuspotential—the system will monitor heat exchange devices 8 continuallybecause pressure drops and heat transfer coefficients will increase overtime or misuse as these are susceptible to corrosion, cross leakage,fouling, freeze-ups, and condensation, all of which are factors thatwill increase heat transfer coefficients and, thus, minimizeeffectiveness. These are the key and relevant items that will beaddressed by said method and apparatus through both flow-pressure andtemperature sensing considerations.

BTUH may be determined entirely by temperature sensor input andcalculation and will fluctuate to reflect changes in increasing anddecreasing load. The accuracy of this method, however, suffers attemperature differentials below 10 and is further confused by theheating advantage of maintaining approximately 90% of heat exchange atonly 50% hot water flow in heating modes of operation. Thus, the mostaccurate method of monitoring BTUH when ideal conditions are notavailable is to monitor water side (GPM) flow rate with a flow meter orcalibrated valve (Terminal Device) and, similarly, establish the totalair side flow rate by way of the flow monitor station 2 simultaneously.

The method and apparatus will perform calculations based on temperaturedifferentials, known coil flow-pressure drops, valve coefficients, andits own air-fluid flow-pressure sensing as set forth in thisdescription, noting any reasonable limitations that would prevent itfrom producing accurate results and displaying them on the userinterface.

Temperature/Density Correction

A correction factor for total airflow measured at an appropriatelysituated flow monitor station, if provided, will be supplied based onany deviation from standard air conditions at 70 F, 29.92 Hg (or 14.696PSI) atmospheric pressure at sea level, specific heat (Cp) of 0.24Btu/lb, and a density of 0.075 lb/cu ft. For other than standard air:V=1096 SQ. RT. Vp/d. Temperature and altitude influences will causethese changes and the system will correct for air-gas temp./density orfluid viscosity. Water does not require correction if measured with theGPM unit, which already accounts for volumetric flow. Standard water:Sea level, 68 F, Cp=1.0, d=8.33 lb/gal (or 62.4 lb/cu. ft. when not usedin a GPM equation.) This is obtained from 8.33 lb/gal×7.49 gal/cuft=62.4 lb/cu. ft.

Fluid density properties will also vary for fluids other than air, suchas gases, glycol solutions, or any other fluid or mixture beingdistributed and delivered in a given or changing state. Correctedflow-volume rates and pressures will also reflect these changes, basedon the given gas-fluids' varying densities and SG's (SpecificGravities.)

Note that either the flow sensing instruments or the temperature sensinginstruments may make these adjustments—relative to any deviation fromstandard air, water and known fluids—but not both.

RH—Relative Humidity

RH may be determined with dry and wet bulb sensors placed at allrequired locations, preferably in an equal area traverse arrangementwhen taken in an open cross-section, such as at an open filter intake.

This arrangement will anticipate air stratification and avert incorrecttemperature sensor feedback due to localized effects, such as thosecaused by stratified air, particularly in a mixing box. Here, airstreams of distinctly differing temperatures, densities, and moisturecontents are being combined quite suddenly, namely outdoor air withreturn air from one or more sources.

When a mixed air enthalpy or content is to be determined in a mixingbox, as opposed to two ducted airstreams wherein they are measuredseparately, a traverse must be performed to obtain truly accurateresults due to air stratification and turbulent conditions, againpointing out another limitation of current sensor use and placement.

Normal sensing locations include entering and leaving coil, outdoor air,and return air, preferably when ducted separately. When they are not,the two must have distinctly original and separate sources, otherwisethe air is already mixed. Alternatively, the combined air may betraversed at the face area of the mixing box as is and results averaged.

Open plenum air handling rooms tend to foster the problem of indefiniteair mixtures with one or more systems sharing return and outdoor airsources and, consequently, load shifting with one another. Also, it isnearly impossible to determine exact degrees of OA or RA content pereach system, let alone precisely adjust them independently of oneanother by damper control. Each unit and heat exchanger 8 should accountfor all air supplied by returning that air in equal measure from its ownzones served, less any outdoor air entering through itself.

Indoor conditions will be quite different from one location to another,particularly in open plenum returns or partial ducted (transfer-type)arrangements, which clearly don't work and cannot be assigned definitiveCFM ratings due to near total static pressure loss. When a questionablesituation arises, sensors should be placed at either a central returnair location or an average taken of all return air locations in distinctzones close to or just inside the register inlets where indoor airsamples are truly representative of indoor conditions, reflectingoccupant loads, equipment, lights, and overall latent and sensibleinfluences after they have taken effect. Odd or isolated zones should beavoided as opposed to central thoroughfares where there is occupancy andkinetic activity.

Latent changes may be viewed in terms of air moisture content, or theaddition or removal of moisture content, which may be expressed eitheras a ratio or actual moisture in lbs/lb or grains/lb, as described inthe previous section. This may also be converted to gallons, liters, orany unit required with or without a flow rate.

Using the correct method and locations for temperature sensing, mixedair is calculated as follows:

% OA=100(Tr−Tm)/(Tr−To)

% RA=100(Tm−To)/(Tr−To)

Hm(mixed air enthalpy)=XoHo+XrHr/100

X=%(OA or RA) H=Enthalpy(OA or RA)

The mixed air enthalpy represents the actual load the coil or heatexchanger has to deal with, not just indoor air alone. Again, moreOA=more load on coil. Basically put, MA is the entering air as a whole.It will be standard for most systems that have outside air or any otherreturning air stream originating from more than one source that will mixwith the primary air and, hence, enter the coil or heat exchange device.The total load (Qt) on the coil 8 or exchange surface will be the totalheat transferred between the entering (mixed) air stream and the leaving(supply) air stream as specified by design. Wet bulb temperatures andthe corresponding enthalpy differential as expressed in the Qt equationnoted previously shall apply. Qs may be used for heat mode, heating-onlysystems, or any analysis reflecting dry bulb (sensible only) changes.

The building load calculation will largely determine the sizing(capacity) of the coil/heat exchange device 8 needed and its resultantpairing with a mover 1 designed to supply the volumetric flow necessaryto distributed this heat flow to meet peak load demand and create airchanges/hr, another code requirement that varies with each type ofdwelling. ACH=CFM×60/Rm. Vol.

Note, however, that, contrary to popular belief and outside of typicallypackaged systems, there is no truly direct or measurable relationshipbetween heat transfer and a CFM capacity rating. It is a unilateralequation, though a CFM rate may be established deductively from heattransfer of a known system in a given context, after the fact. Onefollows the other from contingency rather than necessity. The equationsare still relative, namely to their differentials of temperature andenthalpy. This is where the sizing and flow capacity (CFM) of the moverstands to change for the better with improved flow delivery, from end toend of the distribution cycle. Overall, it exemplifies the distinctadvantage of precise fluidic control, totally and terminally, along withlikewise thermal control wherein they reap mutual benefit.

Psychrometric Chart Display

A full display 6 of all heat flow movement on a psychrometric chart maybe provided for a fully comprehensive analysis of enthalpy changes,sensible and latent heat flow of all airstreams depicted, includingmixed airstreams, effects of adiabatic saturation, lb/lb or grains/lb ofmoisture in air. It may also be used to illustrate actual heat flow byanimating the distinctly horizontal, vertical, and slanting moves thatsensible, latent, and other more complex changes, such as adiabaticsaturation, incur. This may also be used in conjunction with theVectorial Display 6 described in this later section.

Terminal Flow Control and Sensing Devices

Ideally, the terminal flow control 3 and sensing devices 4 are anintegral part of the invention 25 as whole, though one may be viewed asa separate device in the form of a partially retrofitted option on newor existing systems 5. The terminal system 5 and its components areessentially a microcosm of the mover's functions and complement itsperformance in the most effective way possible with the described methodand apparatus air-fluid distribution system and associated performancecurve characteristics. The key difference, again, is that the terminaldevice 3 is a passive one, whereas the mover 1 is an active one.

Above all, the sum of the individual needs of the components of a system5, less diversity factor 22, will determine overall demand on the systemas a whole and it is in the success of these sub-systems that success ofthe whole is largely contingent upon; success here being defined asachieving optimal efficiency of local operations with least total demandbeing placed on the primary mover 1, and, hence, the total power usageof the system in whole; in a given time period, under maximum loadconditions.

It is understood, however, that in a variable system 24, loads arechanging or shifting from one area to another during the course of a dayin an occupied space, and so maximum load per zone is the local concern.The primary concern is the total required for all zones, less diversity22; in so far as the primary mover 1 is concerned and what it may beexpected to achieve. The terms “instant” and “not instant” are used toindicate where and when air-fluid flow and zone temperature conditionsare available at any given time. They are not instantaneous, asair-fluid flow and heat exchange thus produced is directed to where itis needed and when it is needed.

System Diversity

When a diversity 22 is present, as recommended, the described method andapparatus may be used to 1) expand or widen the diversity beyond whatwas previously possible and 2) determine which path(s) of distributioncan best be utilized in dispersing range and run of this diversity,through thermal and fluid mechanic considerations.

FIG. 20 illustrates a shorthand representation of diversity. Theboundaries represent that portion of a system exposed to one side of abuilding or zone and its changing load over the course of a day.

Minimum load conditions or flow positions will automatically beaddressed by the method and apparatus by placing them into the increasedmargin of diversity 22 than would normally be available with currentsystems, as these tend to over-perform at this low end of the spectrum.This may be due to lingering dead bands that linger too long when a zoneseeks to return to minimum cooling or just enough to maintain the “meantemperature average.”

The zone settings and temperatures, however, will always be at the mercyof localized zone sensor placement and/or occupant settings if localcontrol is enabled. Some systems allow local control to be disabled andcan only be set from the main building or energy management system torule out the “occupant tampering” element.

The main problem, however, usually arises from zones whose boundariesare not clearly delineated, or “crossover zones” as we will call them.For example, one branch of a system supplying enclosed offices iscontrolled by a corridor sensor external to the offices and, thus, thisterminal branch's VAV controller and temperature control is dictated bysensor input from an area entirely separated from or only somewhatadjacent to itself. Another example: an open space with cubicles served(conditioned) by two or more different systems with the zone sensorhaving been placed at a far wall somewhere due to construction orarchitectural logistics, etc., and not where the occupants actuallywork. Though rarely seen, some systems use averaging sensors in morethan one location to compensate for this problem. However, the emphasisof these existing systems weighs too heavily on temperature feedback andtemperature sensing in general.

By and large, the described method and apparatus differs from existingsystems with its emphasis on fluidic control, as overlooking this vaststep and placing higher concern with the end result alone (temperature)is a far-reaching problem in itself. The air-fluid's mechanics and thepath it takes to reach its destination are what make the highest demandson the primary mover 1, and hence, total power consumption on itself andthe coil/heat exchanger 8 as well, whether this is a refrigerant orchilled/hot water coil.

If air-fluid is not distributed to a conditioned zone in adequatemeasure, the zone will take longer to cool, refrigerant compressors willcycle up, and chillers will operate on higher load demand as well.Returning air-fluid will have as much to do with this effect as suppliedair-fluid and the obstacles that must be overcome in the circuitous path5 to and from the primary mover 1, or any additional mover within thesystem, or sub-system within the system. Applying the fluidic attributeto existing temperature and load management via temperature control willonly improve these systems vastly and establish the best means ofachieving the required end of automated temperature control systems, asone cannot be correctly justified without the other.

Among all else, the method and apparatus is essentially an intelligentand fully articulated flow-pressure control device, though it willoperate within the framework of any new or existing system 5notwithstanding any limitations of the actual valve or “variable airvolume” terminal 3—in simplest form a motor-controlled damper with adefined range of motion—to which it is fitted. Regardless of theexisting terminal device's limitations, the said method and apparatuswill enable the best possible and most articulated control of thatexisting device and system until a novel VAV, damper-actuator, or valvesucceeds current ones and same principles will apply. In fact, themethod and apparatus will directly result in the development of asuccessive device 3 or mover 1 through its very utilization.

Above all, the method and apparatus will diagnose problems with andevaluate the effectiveness of the existing terminal flow device 3 towhich it is connected, how to best employ its more desirable qualitiesand, in lab use, assist in developing a more effective device for futurefield use.

Lab and Field Use Embodiment

In terms of a significant embodiment, the apparatus and method of such,will also operate as an air-fluid valve flow-pressure metering anddiagnostic device across the valve or damper's full range of motion,establishing unique characteristic curves, along with all describedadvances of current invention. This compound function will enable theapparatus to plot a complete portraiture of all of the valvecharacteristics based on the starting point (constant) of a given totalpressure or total power input. The correction factors for fluids otherthan standard air or water will be applied as constants or variablesaptly noted as such.

Lab Use or Engineering Data

The output display of the method and apparatus will, first and foremost,illustrate how much Total Pressure or power is lost through theair-fluid valve or terminal control unit's orifice, with moverapplication being held constant.

FIG. 11 illustrates the main display of a modulating terminal device 3as it might appear for full evaluation with optional settings for anyand all variables present.

Additionally, the method and apparatus will note and display 6 highlydescriptive information pertaining to the said valve's flowcharacteristics across a full spectrum of effectiveness ornon-effectiveness and may include a traditional Cv (valve flowcoefficient) for hydronics applications, though this considers onlydynamic losses based on an effective area inside a valve or terminaldevice 3 for standard water at 1 PSI of drop in its full open position.Similarly, a K factor or Ak factor negates the SP gradient. Mostcatalogued equipment will simply designate a generic pressure drop in“WC (or “WG) units and so we will distinguish between all unitaryelements at work and their specific role throughout this description.

Referring to FIG. 11, FIGS. 15, 15A, and 15B, once overall loss of TP isexhibited in full open position, a Total Static pressure drop (SP) andVelocity Pressure drop (Vp) will be depicted as well to evaluate testenvironment or “as-built” characteristics. This will also establish adesign method for calculating system friction/head losses and,conversely, those that would contemplate high velocities.

As with the primary mover's Total Gains and Specific Gains, the terminaldevice will illustrate Total Losses and Specific Losses. Above all, itwill answer the following key questions, as posed here:

Q: How much of a total impact loss did this unit create in of itself?Q: How much of the total loss is in the form of SP (Static Pressure?) %Q: How much of the total loss is in the form of Vp (Velocity Pressure?)%Vp/SP ratio or SP/Vp ratio, or expressed as factors.

This will provide useful, if not all required engineering or “labconditions” testing data and is not the same as the field or installedversion, as it is not practical to have this three-fold sensorarrangement in a field version. It is only necessary to establishcomprehensive and official certified data for a catalogued device. Andonce this is done, the device is of known characteristics and itsperformance can then be accurately predicted with simplified sensingelements in field use, and more so with the now fully articulated methodas follows.

Measurements will be taken from inlet to outlet of said valve orterminal control unit 3 to illustrate the loss occurring during theair-fluid's path before and after encountering the terminal unit/valve 3in its full open or other position as arbitrarily set. This will beuseful for design considerations among many other uses. Following thisinitial orientation, a three-part performance curve comprised of TP, SP,and Vp will be plotted across the full range of motion.

The “percentages of content,” a term traditionally used in reference tomixed airstreams, will be determined: SP and Vp of TP. Namely, theVelocity Factor or Gradient of this content will be the keyconsideration in high velocity applications or systems and what remainsis in the form of static pressure. The opposite would apply to highpressure-type applications and systems, where the SP gradient isdominant.

Useful ratios will be noted, from fully closed to maximum flow capacity,so all specific changes, losses, valuable characteristics can be viewed6 entirely across the plotted full range of motion, with the ability to“lock in” all desired characteristics and constants for viewingconsideration for their ultimate effect on the system whole or “bigpicture.” This can be a useful function under changing load conditionsand the various counter-effects that may be imposed to reap addedbenefits of energy management through specific flow control and timelysetting.

The method and apparatus will establish a comprehensive evaluation ofall air-fluid terminal control unit 3 characteristics, their value orlack thereof, in full scope of operation within or without the contextof the total system 5, terminal system 5, and primary mover 1 inwhatever form, number, or combination. This, in turn, will establish thebest suited operating range or point of greatest SP/Vp throughput forthe valve or terminal control device under a given total pressure drop.

This technique, made possible by the method and apparatus, may also beemployed to determine which system 5 or type of system (vessel orconduit of air-fluid delivery) is best suited to that valve or terminalcontrol unit 3 for the desired application. These functions may beserved with or without a “blow-through” or “draw-through” systemattached.

Total Gains/Losses—Specific Gains/Losses

Equipment cataloguing, selection, and system design will be madepossible by the described method and apparatus in its determination ofTotal Gains versus-Total Losses, as they pertain to any primary,secondary, or tertiary mover and terminal devices arranged in series,parallel, or in any other form, number, or combination that producesuseful work.

The primary mover's 1 total gains will be matched to a total system 5,including any and all terminal, in-line devices 3,ductwork/piping/vessel/conduits, fittings, attachments, and all objectscomprising that system through which the air-fluid must traverse toreach its critical run branch 5 and return, less any establisheddiversity amount 22.

In lieu of any minimum or maximum operating parameters 23, the terminaldevice's total losses will be suitably matched to its terminal branchsub-system, falling under total system considerations.

Specific Gains and Specific Losses of all system components will then bearticulated by the method and apparatus, which will then preciselyassess the individual needs of total and sub-system requirements.

The WOC (Wide Open Curve)

To begin with, a “wide open” test can be conducted under defined labconditions, such as those delineated in FIG. 11.

At zero to maximum flow, the terminal flow system's curves (constants)11 are plotted across some degree or percent of “wide open” setting,based on its size and suggested operating range 12, though this fact maynot yet be known until tested and determined empirically. At some valueabove “no flow” or full closure, a minimum flow rate is established.Note that certain minimums are required for terminal devices 3 atdifferent sizes/capacities due to Reynolds number effects as well asterminal heat exchangers 8, such as VAV boxes requiring a heat minimumcutout. Once again, SP, Vp, and TP are plotted as individual performancecurves 11, or flow constants, an option shown at the top left of theindex column in FIG. 11.

Wide open curves were originally established with movers 1 tested underideal lab conditions with no system 5 attached to them, i.e, with littleor no external influence. For example, AMCA has a standard of testing ablower with approximately 10 duct widths of enclosure on the dischargeside, with the inlet being fully open to atmosphere and no otherconstraints on the primary mover itself. This example or any othervariation understood or agreed upon as “wide open” testing may bedefined and accepted as a given precept. In whatever form it may take orimprove on, the forthcoming principles remain the same.

With regard to the said method and apparatus, the “wide open” startingpoint is applied to a terminal device 3 under logic control 9 of saidmethod and apparatus 25, with or without a blow-through/draw-throughsystem attached, thus producing an added claim.

Field Conditions

Under field conditions testing of an “as-built” system 5, best resultswill be achieved if the described method and apparatus 25 is used fromorigination. If this is not the case, “aftermarket” components may beinstalled as a retrofitted option. For example, necessary key systemcomponents may be fitted with some or all of the sensor grids 13, 14, 15or equivalent inlet/outlet-only sensing arrangements, along with theuser interface 6, which may be as large as an entire building managementsystem, or as small as a localized push-button display panel 6.

In any case, utilizing the method and apparatus according tospecifications will produce far superior results than traditionalmethods of sensor control currently in use, particularly with propercalibration using said method.

Furthermore, a known valve or terminal control unit 3 with a known orunknown system 5 attached may be evaluated as well, and vice versa Oncevalve characteristics 11 alone are established, the true operating point10 of an unknown system connected to that valve 3 may be established, aspictured in FIG. 7A.

Terminal Branch System Performance Curves

With its own TP constant 11 and percent or degree opening as a startingpoint, the terminal controller 3 function of the method and apparatuscan determine its actual system's curve 5 and operating point 10 and mayjuxtapose it with the intended one for comparison, if one is provided bythe design engineer or manufacturer's submittal data. This may all bedisplayed on the user interface 6. Above all, it would eliminate anyguesswork and provide a proof for any problematic performance based onknown facts and pre-submitted data asserting those facts.

The curve may be viewed independently, as shown in FIG. 10, or withtotal system curve 5 and mover curve 11 being juxtaposed: FIG. 9, 9A,9B, 9C.

As a recommended option for an existing, “as-built” system 5, theprimary mover 1 can also be equipped with the same conceptual devicethat will plot and display 6 these curves 5, 11 prior to and after thebalancing procedure is undertaken.

The principle operation of the method and apparatus applies to theterminal device 3 as follows: The performance curve will be a compoundone, composed of SP, Vp, and, finally, TP. When the known terminalcontrol unit 3 is placed within the context of a terminal branch system5, it immediately produces a comparison of these three key gradientsagainst its own “wide open” characteristics, these being known andestablished previously. This can, in turn, establish the characteristicsof the system 5 to which it is connected by plotting the coordinates ofboth the real and intended design operation points 10. FIG. 12

Though most system designers, in conjunction with manufacturers, providea “total system curve” 5 based only on the “total static pressure” ofthe primary mover 1, this believed to be a total evaluation of thesystem 5 and has been the basis for sizing the primary mover 1, thisprocedure is here taken much further by having a preset design curve forthe sub-system (terminal branches) as well. In a similar manner, thoughmore advanced, the method and apparatus will establish a design OP(Operating Point) 10 of that sub-system 5 in addition to the primarymover 1, and with a full scope of characteristics rendered for each.Note: If an OP is not provided, a default set point based on thesuggested operating range 12 for that Terminal Device 3 remains ineffect. FIG. 11

The Terminal Device 3 may also adapt itself to the type of system 5 towhich it is connected for peak efficiency, given the existing or“as-built” context of the system.

Evaluation of Known or Unknown Valve Characteristics

Using the method and apparatus testing under lab conditions, themanufacturer's sizing and performance evaluation of these terminaldevices 3 will be based namely on the SP/Vp ratio against its range ofclosure and at whatever throughput one or the other is dominant forspecified effective ranges. This generic starting point may serve tofirst pair a given type of terminal device with either high or lowpressure-based systems. Generally speaking, VAV (air) systems are knownas velocity-oriented systems and so control of the Vp factor becomes akey function. Even so, current systems focus on maintaining constantsystem static pressure at some arbitrarily selected point in adistribution system taking many paths when it is clearly known that thisis the least accurate technique applicable, especially in a VAV system.This is where precise control of both SP/Vp factors becomes not onlyappropriate, but necessary. In hydronics systems, Venturi-type valvessuch as those in calibrated balancing valves are used to minimize totalpressure loss and have an overall high throughput of velocity andpressure—the lengthier, the better. This device is known as a preferredmeans for determining flow in hydronics terminal coil systems, as wellas metering total GPM at the discharge or suction of a primary mover(pump.) Where water or fluids are concerned, the Venturi itself measuresa form of velocity head from upstream (High) to downstream (Low) indirection of flow and has desirable characteristics in maintaining totalhead when the calibrated valve is throttled for balancing, thus loweringits flow coefficient. The Venturi method is also the most accepted meansof determining mover (pump) characteristics via flow metering in labuse, as pressure drops or Cv's are not known until after such knowns areestablished, first through flow (velocity-oriented) metering, thenpressure drop as a secondary function.

Currently in hydronics use, the Plug Valve has the most desirablecharacteristics in some cases with its even curve across a full range ofmotion, without any sharp dips or deviations at the lower and higherends of closure. This is desirable to have at the main pump discharge ora primary loop (main circuit.) Other valves, however, have specific usesfor differing purposes. Commonly found on hydronics sub-loop circuits,Ball and Butterfly Valves may assist in evening out pressure drops and,thus, directing fluid flow to other circuits with steeper “cut-off” andUpstream Leverage, despite lacking “uniform” flow characteristics.

Upstream Leverage

Upstream leverage is another claimed concept in all distribution systems5 that strongly supports the use of Terminal Devices 3 under the controlof said method and apparatus and, above all, the level of precision itaffords to such distribution and delivery. This is perhaps bestunderstood in regard to specific system characteristics and applies toany main branch to terminal control relationship being asclose-controlled to the main duct or primary loop as possible at everycritical juncture.

This method of valve selection, appropriate placement, and articulateutilization of such a device, as with said method and apparatus, clearlyprovides most efficient use of total power and strongest leverage indistribution.

Directing flow to various takeoff branches should occur at connectionsmost adjacent to or as far upstream as possible from main runs, wheremany current systems use face area dampering, such as that employed byso-called “balance-free” diffuser terminal outlets that haveservo-actuated damper blades on the face of the RGD. Clearly one of theworst possible placements of dampers, this causes mainly localizeddynamic (Vp) loss at the face of the terminal outlet diffuser with highSP loss upstream.

Furthermore, almost all of the SP portion of the TP supplied to thatbranch is lost almost entirely to that branch's length of run and,secondly, to fittings, respectively. Pressure loss equals inefficiency,as pressure generation makes the highest demand on BHP and, hence, totalpower; which, if not lost, may have otherwise been available to reachother runs where and when needed.

Consequently, the majority of flow and pressure is not transferred toanother branch via the main duct, but rather is largely lost byremaining stagnant in that sub-branch or loop. This is why air-fluidcontrol via valve or damper throttling to a sub-branch must be made asfar upstream and as close to its main run as possible.

Operating Points

P's (Operating Points) 10 move up and down, left and right,respectively, with effective Static Pressure and Velocity Pressurechanges as monitored 6 by described method and apparatus, wherepreviously this was based singly on static pressure, or total staticpressure where movers are concerned.

The described method and apparatus will, however, take into account alleffective changes, including static, dynamic, and total as well. It willthen make determinations based on how they interact with one another inrelation to the Primary Mover 1, Terminal Devices 3, and the Systemwhole 5.

As shown in FIG. 12, the operating point 10 rides with either themover's curve 11 or, conversely, the system curve 5, depending on whichcomponent comes into play, or is specifically altered while the otherremains constant.

Where a Terminal Device 3 is concerned, its input flow constant simplytakes the place of where a mover curve (@speed of rotation) would be 11.Terminal Device 3 or valve changes of motion ride the valve flowconstant 11, until this is altered, and all changes can be viewed withinthe terminal branch. One or the other variable is altered, therebycausing it to “ride” on the others constant curve. Refer to FIG. 11,FIG. 12.

In general terms, the system curve 5, whether it represents the systemas a whole or its independently controlled branches, is always uniquedue to what is known as its “as-built” characteristics. Despite a designengineer's best intentions, the actual system will always have uniqueattributes that cause it to deviate in one direction or another from itsintended point of operation 10, which is initially established, alongwith mover curves 11, on submittal data at the outset of a buildingproject. With this being the case, the system's operating coordinate 10will ride the steady mover curve 11.

The Sub-System Curve

A sub-system curve 5 for this particular terminal branch system isestablished, as opposed to a total system driven by a primary mover 1.This TB curve 5 transposes and influences the Terminal Device constant11, now with a defined “load” attached in addition to the effect imposedby its degree of closure. Where these intersect is the terminal branchor sub-system's OP (Operating Point) 10. FIG. 9C.

A default setting 12 for this curve 11 will be provided based on themanufacturer's recommendation for this size and range of box, thesebeing previously known and established facts through lab method testingas outlined in this description or otherwise accepted standards. Amongother deciding factors, the criteria may involve inlet size, terminaloutlet (diffuser) sizes, noise, throw, and other related criteria forthe given system or application.

The design engineer may determine his own curve based on whatever uniquecharacteristics his system and/or sub-system may have, or that hebelieves they may have. By its very nature and gradient inclination, thesaid method and apparatus will correct itself despite any oversights,miscalculations, installation problems, etc., in so far as this ispossible with the given constraints of the primary mover 1, availablestock unit, motor, and drive sizes 7, and, above all, the “as-built”ductwork/piping/vessel 5. Wherever these problems may stem from, thegradient factors always break down to Static, Dynamic, and Total losses,leakage aside, though a predetermined allowance should rule out theleakage factor at the outset of system construction. This is furtheraddressed under leakage tester embodiment. Ultimately, a logic-orientedre-plotting of the curves along with juxtaposition leads to the sourceof the problem, clearly bringing it to light.

A Review of the Total System Curve

At the outset, the design engineer establishes the system curve of theentire system 5, this being under full load and full flow conditions,less diversity 22. All systems, including CV (Constant Volume) systems,are begun this way. This initial process is based on the WOAF (Wide OpenAir Flow) of the fan, the primary mover 1 of the entire system 5 as awhole. Subsequently, it is based on the system curve 5 for the entiresystem under maximum demand conditions with the critical length of runor equivalent critical run being a prevalent concern, so that fanpower/pumping power may reach all parts of the system as a whole. Thisis typically a primary concern in hydronics with less emphasis placed ondynamic losses, as pressure losses (length of run or piping friction.)Suction lift in open systems is also of paramount concern, thoughcertainly not the only concern. Along with reaching critical runs inhydronics systems, maintaining relatively equal pressure drops withminimal loss of total dynamic head, particularly around the equipmentroom cluster, is desirable to eliminate any additional head that valves3 and other terminal devices 3 have to deal with beyond this primaryloop. With air, gas, and lighter fluid systems of varying densities andspecific gravities, all the more reason exists to establish specificgradients, namely SP and Vp of TP.

Interactive Concern

Although being pressure independent variable systems underself-calibrating logic control, the sub-systems still need be concernedwith the primary system, mainly to determine if there will be enough ofa minimum operating pressure available at the terminal's inlet. Thiswill be a simple binary decision: yes or no.

The minimum operating pressure will be a measure of TP. The breakdown ofits gradients (SP and Vp) and the measure of specific content willlargely be determined by the selected valve 3 or Terminal Device 3 andits pre-established characteristics 11 as chosen for the application athand.

A common problem in current systems are certain limiting factors whichmay interfere with normal function of the system, such as a blanketsystem pressure-limiting constant being maintained and not exceeded,this to protect the ductwork from bursting at the seams or fittings—orin the case of hydronics, a pump casing pressure maximum. The method andapparatus solves this problem with discriminating sensor interpretation2, 4 and highly advanced logic control 9, which allows the system toexplore venues current systems preclude themselves from by their ownlimiting “blanket” assessments of system control.

The terminal unit's critical run branch will be automatically identifiedand assigned on system startup, whereby all terminal control devices 3communicate sensor feedback 4 and draw value comparisons. Note that thecritical run may change throughout the normal operation of a VAV system24.

System status, however, may change and be reset if more total systempower becomes available after initial startup. This may be due toobstructions later found in the system, clouding its true flowcharacteristics or, more commonly, if smoke dampers at firewallpartitions are found to be closed, completely altering the system curve5 profile. Also note that the furthest branch is not necessarily themost critical, as the “equivalent” furthest branch is often a tightlywound branch somewhere at midpoint in a system branching out in alldirections. Equivalent means the calculated total losses of theair-fluid path to and from the primary mover (dynamic and friction) arehigher, not always due to length of run or distance away from the mover.Once again, this former assessment of critical run is based solely onstatic pressure.

Here is another pivotal adjustment pointing out differences in existingsystems, though no known previous automated system ever established anycritical run, rather leaving this process to the balancer for creativeinterpretation. And those in practice that may establish this criticalrun do so with only static pressure readings, not total (impact)readings, again ignoring the velocity gradient. SP increases alone mayand will result from undue system restriction and not from mover poweras applied effectively.

Under control of the method and apparatus, the Terminal Devices 3discussed here will use their own internal impact sensors 13 to make thecritical run determination, not their static sensors 14 with which theyare also equipped and make use of appropriately.

Primary Mover—Terminal Control Relationship

Alternatively, there may be fewer losses than anticipated, as is commonwith hydronics systems, after a multitude of safety factors and otherconsiderable allowances are made. This being the case, the method andapparatus can adapt to this and make the delivery of flow more useful atsome other location and, ultimately, “ramp down” 7 the primary mover 1,causing it to utilize less total power. This may be accomplished by wayof mover speed control 7, such as that achieved with a VFD (VariableFrequency Driver,) which most current VAV systems are equipped with asan alternative successor to Vortex Vanes. Now virtually outmoded, thesewere affixed to blower inlets and contributed to the adverse conditionknown as system effect losses, irretrievable dynamic losses occurringparticularly at a blower's inlet. They were also obviously without theadded benefit of motor speed reduction at the expense of undue systempressure increase and total pressure/power loss.

Now in wide use, VFD's operate from 0 to 60 HZ and up to now have usedthis variable only to maintain constant pressure as sensed by a singlestatic sensor placed approximately ⅔ into the system. In contrast, thesaid method and apparatus described may utilize this speed controlvariable 7 correctly, whether it be via VFD or any motor with speedcontrol not dependent on the concept of VFD or any other brand concept,to extract added benefits from the mover 1. Note that the aforementionedsensor-VFD system is the least effective means of total system control,as it is governed by a general rule of thumb, subject to misleadingresults and fluctuating circumstances abundantly clear to theprofessional experienced in VAV systems.

Static Pressure Control

This leads to the problem of static-pressure sensing control in general.It will always be misleading due to system constraints, such as blockageor restriction inside of ductwork which will inaccurately reflect howmuch of the static reading itself may be attributed to fan power asapplied effectively or fan power being held back by undue restrictionand, thus, converting to static in whole or part, again at the expenseof dynamic losses. To emphasize this point, if a single duct outlet wereto be capped entirely, the total fan power would convert to 100% staticpressure, this never being more than or exceeding the fan's known totalstatic pressure itself at any given point in a system.

In actual practice, SP sensing alone does not equate, per se, to acorresponding flow rate for a known device within an unknown system 5,these tested with same current methods. And technically, any “as-built”system may be called unknown. SP sensing may suffice, however, foroperations whose function is to maintain pressure constancy, such asbypass/relief functions, where flow is of no consequence. The staticpressure profile is suited to this as well, where a packaged unit andpractical field considerations are concerned.

If more than one mover 1 is involved, then two or more in series 16 willcombine total pressures, approximately—not exactly—in equal measure,and, conversely, parallel arrangements 17 will approximately remainconstant on pressure and double on flow, assuming each are of similarsize and capacity. Note the augmentative effects these arrangements haveon movers in FIGS. 14C and 14D.

Mover aside, this same principle holds true for Terminal Devices 3 (inseries 18 or parallel 19,) most often used for reheat cycles infan-powered VAV terminals by introducing induced plenum air at one ormore stages of heat and/or fan speed that occur intermittently. In HVACapplications, these are used primarily for perimeter areas of abuilding. Note the augmentative effects these arrangements have onTerminal Devices in FIGS. 15C and 15D.

Additionally, induction terminals, with or without secondary fan power,stand to benefit from higher velocities by inducing secondary air moreeffectively and avoiding additional fan power requirements, if notentirely.

The specific contents of the total power applied potentially throughoutthe system 5, will largely be determined by the primary mover 1characteristics 11. Again, high-pressure type movers have thecharacteristics of higher static output with a smaller velocitygradient. The lower-pressure type, an extreme example being a propellerfan (axial type,) produces higher flow-volume at the expense of staticpressure. Taking into account varying characteristics among them,centrifugal fans typically produce the higher pressures, particularly BI(Backward Inclined,) while axial fans produce high flow, high volume andare best suited to those applications, such as smoke evac systems forwide open areas.

Each basic unit is specifically chosen for the task it is designed andbuilt for, with many variations in between affording it the benefits ofeither. Thus, beginning with the primary mover 1, the described controlmethod and apparatus carries this underlying theme and the pressuregradient concept with it through to each and every terminal branch ofthe system 5 and this pervading point will be emphasized throughout.

However, this concept may be taken further when the context of thesystem is viewed as a whole environment. For example, if total systempower is not available or has “ramped” down 7 to maintain a constantsystem static pressure and, consequently, some of the VAV terminals maybe starved for air. This may be due to a diversity factor 22 and, thus,total air per terminals/outlets exceeding the fan's total capacity, asis typically the case.

If a particular zone requires more air due to load changes or unusualshifts that don't follow the predicted movement of the sun from East toWest, the terminals may strike a compromise among other zones that maynot require as much air flow. This may be achieved by having thoseterminals (usually adjacent ones) close slightly on cue, until adequateinlet flows/pressures are obtained at the terminal in question. This“squeeze” can help boost nearby zones just enough to cover lean periodsand return to normal default operation.

The system may also perform a timed tradeoff, so to speak, byalternating availability of operating pressure to needy terminals, whilestill maintaining zone temperature set points, which will tend to lingerwith adequate insulation and generous load calculations whether or notthe desired air changes are occurring in the building/zone.

Falling short on total system pressure (typically a static measurement)is the most common problem with current VAV systems 24, particularlythose with a diversity factor 22, the end result of this often beingthat the VFD remains at or close to its full speed (60 HZ) operationmost of the time, defeating its own purpose to begin with: to maintainconstant though often inadequate system pressure and, presumably, flowrate to all branches 5 at a lower total demand on the primary mover 1.Here may lay a strong defending argument for old vortex vanes, which atleast maintain a degree of system pressure, albeit at the expense ofdynamic losses.

Another interactive example could involve ramping 7 the primary mover 1down indiscriminately to conserve energy if all zones achieve theirtemperature set points, still taking minimum air changes (air changesper hour) and minimum fresh air requirements into account, these beingpredicated by ASHRAE standards and other municipal building coderequirements.

This process may allow the fan 1 to slow down below its system staticset point, so this factor alone is not the only deciding one.Maintaining suction pressure and flow rate, however, are often one ofthe most difficult challenges when ramping down or lowering fan speed 7in any way, and the suction side or mixing box intake is one of thefirst casualties of lower fan speeds in the framework of an “as-built”system. One of the biggest challenges is the problem of the OA damperand mixing box controls maintaining adequate OA flow in a VAV system 24in constant modulation, with a pressure limiting constant, and moverrotation variable 7. Designing these systems is not impossible, but themargin for error greatly diminishes and, therefore, preciseflow-pressure control becomes imperative.

Mover systems equipped with the ⅔ rule static sensor are meant tomaintain a constant system static pressure (usually 1.5″) to protect theductwork for its class and rating when VAV terminals throttle back and,hence, increase system static pressure, placing the ductwork underincreasing duress. However, most systems' effective operation is at themercy of where these sensors are placed, or able to be placed due toaccess and logistical issues. And the question remains whether theselocations are truly representative of the system as a whole. Beingsingle point static sensors in multi-directional ductwork with variableairstreams undergoing constant conversion, it can reasonably be deducedthat they are, in fact, not providing uniform or reliable feedback ofwhat the system in whole or part is experiencing, and are largelygoverned by a rule of thumb.

Depending on the complexity of the system 5, (number of take-offbranches, fittings, etc.,) the static feedback alone will varyconsiderably from one definitive portion of the system to the next,especially under VAV control with widespread fluctuation at all times.

This being noted, the function of the air-fluid distribution system 5 asa whole is best served by having comprehensive, definitive, andintelligent sources of feedback from the terminal branches 3, 4, assupplied by the described method and apparatus.

System Flow Diagram

Beginning with the Primary Mover 1 and the Total System characteristics5, the logical decision-making process will follow a “hierarchy” of thesystem on start up. This will lead through to each Terminal Device 3 andterminal branch, wherever a flow monitor station 4, meter, or anysub-circuit control system is located.

The sequence of operation will adhere to, but will not be restricted bythe procedure of the method and apparatus as outlined in thisdescription, though any omissions due to unknown or previouslynon-established effects will be duly accounted for by way ofupgradeable, tabulated databases 9. These will include any and allpertinent data, such as late mover equipment (blowers, pumps, motors,drives, etc.) and late system construction components (ductwork, piping,vessels, conduits, Terminal Devices, etc.)

The expandable databases 9 will also include any and allscientific/engineering data pertaining to thermal and fluid mechanics,such as psychrometric data tabulated in tenths of degrees or lower, andduct/piping friction loss/head loss tables, fitting loss coefficients,Reynolds numbers, and any K/Ak-factors predetermined or as establishwith said method and apparatus.

The system flow charts may be viewed in FIGS. 21, 22, 22A, 22B, 22C, and22D. After initial menu selection for type/classification of system(FIG. 21,) the process begins with System Start and key determination ofsystem status, as shown in FIG. 22 (air) and FIG. 22A (hydronics.) Firstof all, the system will establish mode of operation, Total system OP 10,target speed of mover rotation 11, and all procedures as outlined inthis description, beginning with “Initial Operating Point for SystemTotal.” 10 The schematic layout essentially reflects the structure ofthe user interface panel 6, where a number of key options will beavailable for selection.

The System Modes will establish what initial setup the primary mover 1and main damper control 3 will have to activate for the desired mode ofoperation. Of these will be included: Normal Mode Op, Smoke Mode Op,Balance mode Op, and Test Mode Op.

With regard to the Terminal Device flow chart (FIG. 22B,) these optionswill extend to operating mode parameters, namely the following: MIN(Minimum,) MAX (Maximum,) FULL OPEN, FULL CLOSED, AUTO—HEAT, andAUTO—COOL. The MIN/MAX parameters are intended mainly for Balance ModeOp, wherein these parameters may be calibrated in an unknown or“as-built” system for testing and balancing purposes. The FULLOPEN/CLOSED parameters will be intended mainly for Smoke Mode Op, suchas for purge systems or auto “shut down” systems. They may also be usedfor any form of “wide open” system testing, with or without a diversity,which may be done in Test Mode Op.

Note, however, that MAX conditions are not FULL OPEN conditions, as thesystem characteristics 5 will not be the same when marked against themover characteristics 11, thus misrepresenting the true system operatingpoint 10 as intended. The terminals 3 equaling the diversity amount 22will also be either FULL CLOSED or in MIN position to accurately reflectthis condition.

Other initial options include DISPLAY SYS DIVERSITY and MAP SYSDIVERSITY, a selection which allows the “as-built” system to be analyzedin whole and part under set conditions to map the most appropriateterminal runs for inclusion in the margin for diversity 22, namely thosethat are the least critical. This will be determined by sensor logic 4at each terminal device 3 and value comparisons drawn after establishingthe most critical run. Terminal Branch system operating points 10 willalso evaluate these runs on a per branch basis, in whatever scope orportion of the total system is desired, as the gradient breakdown ofthese sub-systems may be either complementary or rudimentary to theprimary mover. Runs may also be assessed in any mover-system or terminaldevice range, speed, position, and infinite or finite combinations ofmover-system-device changes.

The diversity 22 then becomes another useful proponent in the system 5,and may or may not be changed arbitrarily. It may be discovered, forexample, that wider diversities are available with seasonal changes orwith load occupancy changes. Otherwise, a fixed diversity amount ispre-established for specified conditions.

ZONE SENSOR FEEDBACK may also be prioritized, localized, averaged, oromitted for any particular zone or terminal device. This way “crossoverzones” and other undue external influences won't cause the system tomisinterpret load changes or demands for that zone served by theterminal branch. Also, the sensing logic may be oriented around areasthat reflect the largest, smallest, or mean demand, as selected. Resultswill differ with each project, but the method and apparatus provides thetools to best tailor these variables on a per project basis for thedesired results, thermally, statically, and dynamically.

FIG. 21 shows how the main menu display 6 might appear to allowselection from a variety of distribution systems 5. It also allows thekey option of enabling DEFAULT OPERATION. This option will produce thebest results when the described method and apparatus is used fromorigination, but may also function in an “as-built” system that hasundergone initial testing utilizing said method and apparatus.Essentially, it will place all components of the primary moving unit andsystem at settings that will be indexed according to its ownpre-established criteria or suggested operating ranges 12 for movers 1and Terminal Devices 3.

This initial mode of operation will also enable the system to “learn”about how the many variables in the distribution system come together toprovide the best results, desired results, or most effective operationthrough computer-assisted calculation of run possibilities and diversitymapping. In this sense, it may function as an AI (ArtificialIntelligence) system. Limitations will be imposed only by the size andscope of its database, and this will grow in short time with empiricaltesting utilizing the principles and procedures outlined in thisdescription. Ultimately, its faculties allow it to interpolate ratherthan extrapolate data, which is a key fault in current theoreticalprojection of “would be” system operation. As mentioned previously, thisproblem stems from contingency rather than necessity.

Given the size and scope of currently available data in aging, thoughneglected reference texts, an enormous lexicon can already be built onexisting data alone which has until now remained untapped. Adding tothis problem, many fundamentals have been grossly overlooked in currentsystems and crucial lessons in the advancement of these technologieshave been skipped. Simply identifying these may solve long-standingproblems in the state of the art. Such a lexicon can be advanced andcultivated by the described method and apparatus, allowing it to achieveomni-presence in environmental systems through sensory interpretationwhere this was not previously possible.

FIG. 22 illustrates the air system flow chart. FIG. 22A notes the keydifferences for a hydronics system 5. FIG. 22B represents the layout fora terminal device 3, after initial system setup has occurred andproceeded to this point through user acceptance or default setting.Finally, FIGS. 22C and 22D present a Possibilities Display Menu for airand hydronics systems, respectively. This is intended fortroubleshooting hardware equipment failures that would prevent thesystem from proceeding through each sequence or step of its operation.The notable feature employed in doing this involves using describedmethodology and sensor logic for determination of where the problemoriginates from, namely whether it is internal or external to theprimary mover 1 and/or terminal device 3. It will also determine thenature of the problem by the gradient inclination (TP, SP, Vp) outlinedin this same description. The Possibilities Display 6 is alsosupplemented by an expandable database 9.

Vectorial Analysis

FIG. 19 and FIG. 19A show a vectorial depiction of all mover 11 andsystem 5 changes which may be viewed superimposed on the actual maincurve displays 6, or viewed separately as changes occur in real orsampled time periods. This provides a “bare bones” rendition of anydesirable or undesirable changes, which may be occurring within eachcomponent of the system. The vectors may also portray mover and systemchanges imposed arbitrarily when viewed as a whole or independently. Inwhole or part, each component may be compared and contrasted.

One example would show how changes to a sub-system affect a primarymover's BHP and SP, or vice versa. The encircled cross hairs representthe total or sub-system OP (operating point) 10 and this may beuser-manipulated for design or testing purposes, so the total andterminal effects of an entire air-fluid distribution system may beviewed prior to any system being built.

Using known equipment data as referenced from its own database or otheraccepted sources, the method and apparatus can function as a virtualsystem for HVAC or air-fluid distribution system performance.

All equipment performance and selection data may be provided, fromprimary mover 1 and terminal device 3 sizing down to final drive 7adjustment to the motor, though this data may be too precise for actualstock sizing available. Whatever resources are used, an added claimstands to improve the precision of equipment sizing if said method andapparatus is used from origination.

An upgradeable, catalogued database will be referred to in the course ofsystem design and selection, though ultimately, this will be a userdecision. Actual system and sub-system data will draw from databasestorage of ductwork/piping/vessel fitting loss coefficients andfriction/head loss data, as this may need to be stored and retrievedfrom a timely source. Equipment sizing and capacity may be enteredmanually, however, from tabulated data or other reference materials asan added option. User or default options will allow flexibility in thisarea Ultimately, if computer assisted design is integrated from thedesign stage, system data may be carried over from this stage, whetherfully automated or prepared by tabulated references and calculation.

Fluid changes may also be viewed in tandem with load (heat flow)changes, so one may visually depict how the other is compromised oraugmented by the changes. This display may be shown in any form, numberor combination of components, depending on the size and scope of theentire distribution system.

Final Recommendations for Equipment Sizing, Capacity, and Performance

After the described method and apparatus performs the task of evaluatingthe entire system and all of its components, it will collect, calculate,tabulate, and display the results of its findings from a key menu listbeginning at the top of the hierarchy for that system, from the primarymover on down. There may be one main menu listing all directories and/orsub-menus if, for example, there is an air system and a hydronics systemwith chillers and a cooling tower. These key categories can be separatedaccording to their classifications and mover characteristics, this beinga pump in the case of a hydronics or fluid delivery system.

The final collation command may be requested when the buildingmanagement systems operator or, more appropriately, the testing andbalancing agency, has decided that the preliminary testing, withexisting conditions being constant, has been performed to requirementsand meets acceptable standards. The findings may be accompanied byspecific recommendations and sizing or re-sizing of equipment capacitiesfor first cost or long-term benefit, or this may be left open tointerpretation by simply presenting objective final results in the formof plotted curves 11, 5, operating points 10, and statistical figuresevaluating all relevant components of the system, including individualand total final power input/output. The presentation of this informationshall be orderly and reflect key aspects of the distribution system in aclear and concise manner, emphasizing a standard for prioritization.

The final deduction of all system characteristics will be reduced tototal power (or wattage) consumed by the system in whole, along with thepower produced by the primary mover. Totally and terminally, this mayall be broken down into BHP, kilowatt input/output, and BTUH or MBH heatflow. Following this, a breakdown of the system's individual componentswill be analyzed, including specific heat transfer in BTUH andeffectiveness of heat exchangers. Parallels may be drawn between air orfluid flow and electrical flow, with each system component having itsown characteristic effect on localized and general power draw.

Typically, amperage use will increase in high velocity applications and,conversely, voltage will increase in high-pressure applications. Thisway, the actual contents of Total Power may be assessed and tailored tospecific systems. A more detailed analysis may identify how variousconversions of TP throughout the system play on the total system powerdraw under varying loads, demands, and differing conditions asarbitrarily set.

If shop drawings are available or integration with a computer assisteddesign system becomes possible, the sizing, shape, and fitting of allmain and terminal branch runs 5 will be suited to or contrasted againstknown or projected operating points 10, based on intended design or“as-built” configuration.

Motor and Drive Replacement Recommendations

Using the following equations, the method and apparatus may recommendpulley and drive sizes as well as motor sizes 7 by direct BHPcalculation, if required. Also, “tag” HP may be obtained from stocksizing, as would be readily available from its database.

FRPM/MRPM=MPULLEY SHEAVE DIA./FPULLEY SHEAVE DIA.

FRPM—Fan RPM (also, driven RPM)MRPM—Motor RPM (also, driver RPM)

D—Driven Pulley

d—Driver Pulley

C—Center Distance—Bore to Bore

L—Length of drive belt

The FRPM, or driven speed of mover rotation 11 required, is determinedfirst from actual total capacity CFM of the primary mover 1 andcorresponding FRPM at this flow rate as tested within a real “as-built”system under constant, pre-established conditions. All data is obtainedfrom the sensing apparatus as previously described.

If the flow rate does not meet the specified amount totally 2 orterminally 4, a complete review of system characteristics 5 may berequired, and said method and apparatus 25 provides all the means fordoing so. This would bring under scrutiny any ductwork, fittings,terminal devices, or other components of the system that may contributeto this adverse effect, as previously described.

If the system is otherwise accepted, the relationship as follows isdirect to flow and, thereby, a new FRPM and corresponding driver pulleysize is calculated for the new required flow rate. Alternatively, a fanpulley size may also be provided, though this method of adjustment isgenerally not recommended if the fan falls below a 1:1 ratio with themotor pulley, along with other motor-mover considerations involvingstability of operation and maintaining an adequate center distance. Forprevention of early wear and failure, the angle of drive belt to pulliesis usually kept under forty degrees. Erroneous drive choices, however,will be limited by stock sizing guidance in that incorrect drivearrangements will normally not be compatible with motor frame, bore, andother standard sizing, unless there are more serious design flaws.

Belt size: L=2C+1.57(D+d)+(D−d)SQ./4C

FRPM ratios are cubed to brake horsepower, so the projected FRPMdetermined at the final required flow rate of the given system 5 willalso provide the suggested brake horsepower required at this operatingpoint 10. We must assume, however, that the original design figure andcatalogued equipment characteristics have been correctly applied forthis logic to work. It must be remembered, however, that an element ofcontingency still remains here. An estimated FRPM and resulting flowrate 2 may be figured by pulley and motor tag data, along with any moverperformance curves 11 provided by the manufacturer, though this usewould be suggested only as an additional point of verification.

Note that fan speed 11 and BHP calculations from actual power draw areconsidered the most reliable field measurements in an “as-built” system5 and static pressures are the least. This again supports the need fordynamic and total sensing considerations, because where unknowns exist,they may always be determined with the described method and apparatusthrough interpolation of available, correctly obtained data. BetweenTotal Power and Total Pressure breakdown, there will be no unknown thatcannot be deduced (as opposed to induced) by this method and apparatusunder actual operation of a real system. And prior to this, theprojection of design operation will be most accurate if the method andapparatus is used from origination, this simply making any extrapolationof performance characteristics more viable from the outset.

Ultimately, the test required to establish the “Initial Operating Pointfor System Total . . . ” 10 will re-affirm true performancecharacteristics once repeated by the method and apparatus with the newmotor and drive configuration. This initial process will establish thereal OP 10.

Normally, if the deviation is not great, the same motor and drives 7 maybe used, if there is a VP (Variable Pitch) adjustment 7 with room lefton the driver pulley for an FRPM increase or decrease. An increase willalso increase amperage draw on the motor, which should not approach orexceed the service factor on its tag, and this will be the usual commonsense indicator to those practicing the art that a motor and pulleychange may be required if flow rates and pressures are still notachieved. In some cases, only a pulley adjustment may be needed, justuntil the motor is drawing full load amps. Beyond this, a motor changeat the corresponding BHP or stock size equivalent may be necessitated.If stock and frame sizes are greatly exceeded or receded, this isusually an indicator that the mover is improperly sized or that thesystem connected thereto is ill suited to its primary mover.

Hardware Requirements

Hardware components governing the method and apparatus will be comprisedof a central processing system (micro controller) 9 in one or morelocations, and sensing elements 13, 14, 15 in arrangements described anddepicted 2, 4. Local control through open architecture, or Ethernetreflect some of the prevailing trends in building control systems andthe described method and apparatus may or may not be accommodated to fitwith these current trends for compatibility.

Logical processes and programming shall conform to but not be limited inscope of operation by flow charts as shown in drawings. The main controlsystem 9 may be implemented through any programmable micro controller 9or EEPROM with typical inputs/outputs and universal logic control.Displays 6 may be either full monitor stations or smaller push-buttonpanels for complete or retrofitted systems. The user interface 6 willhave portability for connection to local LAN's (Local Area Networks,) ormore centralized networks. Whatever the hardware or software, oroperating system technology employed, the system remains as a separateand distinguished entity not bound to conform to any existing or novelhardware/software system limitations or restrictions.

When terminal flow device 3 characteristic curves 5 and system curves 5are being established across a full range of damper/valve motion, themicro controller type and quality will determine how resolutely and,hence, precisely the range can be monitored. The micro controller willinterpret and process the transducer signal to a degree of precisionafforded by its own internal scale. This range will also define theincremental spacing within the parameters of the damper/valve's fullrange of motion from 0 to X flow at given pressure gradients.

As stated in the background, the analytical plotting of curves 5, 11will supercede current systems' linear tendencies by establishing thedescribed thermal and fluid mechanic relationships prior to effectingmotor control 7, 3. This avoids direct modulation along theprocessor-motor controller's linear scale of motion, as currentdirect-acting control systems are prone to slavishly follow. Precisionwill also be afforded by the quality of the sensor transducers, whichconvert the pneumatic or fluid signals into electrical ones.Notwithstanding hardware limitations, the operating principles of themethod and apparatus will be retained and results will only improve withhardware development.

A stepper motor or similar motion control device shall be therecommended means of damper/valve control 3 employed to establish aclear, graduated range of motion in harmony with the micro controller's9 capabilities, and each increment will be broken down into radians ofmotion to precisely coincide with percent or degree of damper/valveclosure.

Sensing instrumentation, in its most basic form a U-tube manometer ormicro-manometer, will “sample” flow rates and pressure gradients, thus atimed, metered signal may be generated in every one second or higherintervals, also dependent on the nature of the micro controller. Thereadings are then averaged within a given time frame. This samplingduration variable may be set arbitrarily, though a five second samplingof a sensor transducer signal is commonly adapted when taking an“instant” reading. Other more precise applications, however, may requiresampling occurring within a fraction of a second, such as that describedin “Determining the Volume of a Given Vessel or Enclosure” embodimentdescription. A sampling's total duration may be entered arbitrarily inthe TEST MODE of the method and apparatus for a short or long-termanalysis, as desired or specified. Alternatively, flow rates, pressuregradients, thermal relationships, temperatures, and overall mover andsystem characteristics may simply be monitored in real time with allrelated factors coming into play.

Overview

The total flow-pressure power passing through the measuring device (TP)is made up of SP+Vp. It is known that these two are mutually convertibleat various points in an air-fluid distribution system and that TPdecreases in the direction of flow. Static pressure tends to regain some⅔ of the way into a duct system after exiting the mover's discharge; atthis starting point much of the mover's total power being in the form ofpure velocity, until it “solidifies” into pressure downstream. Themethod and apparatus isolates these key analytical elements anddetermines their specific usefulness within an air-fluid distributionsystem.

The method and apparatus will determine how much of that total power isin the form of dynamic flow and how much is in the form of stagnant air,gas, fluid, etc. When TP=SP, there is no dynamic flow, hence zerovelocity. The total applied power is in the form of 100% static pressureso long as mover power is applied. For a flow control device and primarymoving system as a whole to assess useful flow characteristics, the TPmust contain the right measure of both ingredients for the intendedpurpose. Both velocity and static pressure gradients are needed toprovide total “strength” in distributing air-fluid to various parts ofthe system with a changing ductwork/piping landscape.

A preponderance of one or the other elements typically creates animbalance, though it may also provide a useful purpose if manipulated.For example, velocity-based flow's notable characteristics are speed,volumetric flow, inductiveness, and penetrating ability. Namely, thistype of air movement establishes the flow rate or flow-volume (CFM)passing a given cross section of the duct. High velocity jets are knownto foster the induction process, for example in induction terminal boxeswith a primary nozzle supplying high velocity air, which induces asecondary air stream of a relatively higher pressure.

Static pressure provides the lateral force needed to overcome frictionlosses (or length of run, which may include roughness factors) and mayexist dormant within the system as pent up potential energy that mayonce again be expelled in the form of velocity during the conversionprocess. This occurs at various points in the system, as dictated byexpansion, reduction, and direction in ductwork/piping fittings. Thesecomponents can be compared to amperage (rate of speed, kinetic movement,cycle) and voltage (applied pressure or force, potential energy) inelectrical engineering or general scientific terms.

There are three key forms of losses associated with ductwork airdistribution and fluid distribution in general: 1) Dynamic losses,associated with fitting loss coefficients and measured against velocity.2) Friction losses, associated with length of run and roughness factorson the surface of ductwork/piping/vessels, all measured against staticpressure. 3) Leakage losses. Simply put, holes in the duct/piping/vesselbleeding air-fluid at a defined, constant rate per surface area. Thismay be in the form of exfiltration (going out) or infiltration (comingin.)

In current practice, specific losses, namely dynamic, are ultimatelyconverted to “inches of static pressure,” the common accepted languagefor sizing of mover characteristics. The length of run is already basedon an assigned static/head loss per 100 ft of ductwork/piping asdetermined against round duct conversions or piping charts. Finally, atally of all losses is made and figured in “WC units of total staticpressure, or Total Feet of Head in the case of hydronics. This figure isthen plotted as the Total Static or Total Head system curve. Ultimately,the primary mover's total power must meet or exceed this sum amountwithin acceptable tolerances. However, the dynamic aspect of thisequation is not apparent to a flow sensor that measures only staticpressure within a system, or only velocity pressure within a system.Even total pressure as a solitary gradient within a system is notadequate. Current sensing equipment cannot differentiate between thethree after the fact, after the design total is figured from semanticsbased solely on a general rule of thumb or other pre-conceived ideas.

Beginning with the primary mover 1, the said method and apparatus'sunique sensing functions 9 extend to the system 5 as a whole and make ita complete, stand-alone system with no previous platform derived fromcurrent systems. The method and apparatus of total and terminal controlis able to measure every aspect of air-fluid and thermal flow brokendown into its prime components and make valuable, calculated assessmentsas to its usefulness or inadequacy for the specified purpose. It alsoplots exacting curves of all pertinent performance characteristics,including that of the primary mover 1, terminal flow control 3 and heatexchange devices 8, and their correlation to main and sub-branches 5.

Percentage of Content (SP and Vp of TP)

Just as mixed air streams have been tested to establish percentages ofOA/RA content of Total Air, similarly, the specific content of SP and Vpof TP (Total Pressure) can also be established. The percentage ofcontent will also be indexed on a user interface 6, along withjuxtaposed performance curves 5, 11.

Ideally, a shop drawing may be required of all “as-built” ductwork toobtain exact fitting, area, and length of run dimensions to determineexactly how these pertain to the monitored flow-pressure characteristics2, 4. The described database may also contain all this standardizedinformation for immediate reference and curve plotting, particularly ifcreated and stored on the same system or retrieved from a computer file.

Varying flow characteristics are necessitated in a broad range oftechnological applications, from providing a defined sweep pattern ofairflow across a clean room to applying exact amounts of roompressurization differential in a hospital operating room, or within somecontained vessel. Particulate control and highly articulated control ofmixture/gas delivery may also be achieved. Smoke control and relatedsystems stand to benefit from this method and apparatus as well.

Smoke Control Systems

Generally speaking, smoke evacuation (or exhaust) systems require highvolume, high velocity flow for evacuating smoke as quickly as possiblefrom large open areas, such as hotel or condominium lobbies, conventionhalls or auditoriums. On the other hand, smoke purge (or pressurization)systems require higher pressure-based systems to purge egress corridorsand create pressure “sandwiches” that isolate occupants from an area ofincidence where a fire and resulting smoke originates. This area is inturn evacuated (exhausted) or system shutdown occurs to prevent furthermigration.

Purge systems also serve to pressurize stairwells and elevator shafts,two highly critical concerns of a smoke control system, particularly inhigh rise buildings that often experience high pressure loss andfluctuation due to building envelope leakage, infiltration orexfiltration. This is particularly true of elevator shafts, which sufferthe most from this problem and, additionally, have an extensiveroughness factor due to CBS construction. If not adequately pressurized,however, they may be susceptible to becoming a vehicle of smokemigration. Still, this remains a source of debate due to many otherinfluential factors coming into play, namely windage and buildingstacking effect.

A building stacking effect is formed by a downdraft in warm climates andan updraft in cold climates occurring in the building core elevatorshaft. These drafts are mobilized by indoor and outdoor temperaturedifferentials that influence the pressure profile from top to bottom ofa building. This effect can only be overcome with correctly applied fanpower, a possible relief system, and consistent distribution from top tobottom. Windage is also an influential factor, creating a positiveinfluence on the windward side and a negative one on the leeward. Thisoccurs through infiltration/exfiltration of the building envelope,tending to “skew” the pressure profile of the shaft like an uneven deckof cards.

Clearly, this problem presents a design-build challenge from anyperspective. Above all, these influences leave little margin for errorin providing adequate pressure in any tall column, such as a stairwellor shaft to be purged and, thus, made immune to smoke infiltration. Anextensive length of run and roughness factors, due to the vessel notbeing a smooth conductor, necessitates a high-pressure application.Distribution aside, correct mover selection to start with is the keyremedy in smoke control systems. Typically, vane-axial fans are used for“evac” systems, and higher-pressure BI centrifugal fans should be usedfor purge systems where taller buildings and extended shafts or columnsare concerned.

Other Uses

Another basic example involves the portion of an air distribution systemwhere air exits into a conditioned space. The discharge point where theterminal air outlet (diffuser) is located requires a high velocitycontent to develop an adequate throw pattern, isovel, and overcomefitting (dynamic losses) associated therewith. The air requires a total“push” to move it an adequate distance, then requires a speedy deliveryfor its final exit. However, the primary air temperature, the roomtemperature and its pressurized (stagnant) or otherwise fluentcondition, all contribute to the form of the isovel. These factors alsodetermine the throw and speed and in what manner the room air (secondaryair) entrainment occurs under the terminal discharge of the air-fluid,prior, of course, to its re-circulation. Thus, utilizing the method andapparatus, throw patterns can be more precisely applied and formed inexacting detail with both thermal and fluid mechanics considerations. Inthis usage, zone sensing may be applied to control the effect of thegiven room, vessel, or any other enclosure. The isovel may perhaps beviewed with thermal or infrared viewing to observe its actual shape andfiligreed form. Such an observation may serve a purpose with otherfluids, such as gases or air-gas mixtures with or without combustionand/or thrust being produced for specific and useful work. In this sensea terminal diffuser may be likened to a thrust nozzle, a fuel injector,or any terminal device of delivery.

The room, compartment, or enclosure itself may also be viewed as acontained vessel against which static pressure is measured, or againstwhich a differential static pressure is measured from room to adjacentroom/area. Typically, the arrangement may be such that all rooms withina building are relatively lower in pressure to this core area up to theouter bounds of the building envelope and out to open atmosphere. Thisfunction may serve a room pressurization application, such as that usedfor medical or clean rooms. Using the method and apparatus and theknowledge that precise force can be applied where 10″ WC equates to 5.2lbs/ft Sq. of force over area, this may be used most effectively. Theenvironment can also be controlled under varying conditions to meetpreset parameters for desired building pressurization. This may be doneon a per room basis with a consideration of all rooms and changesincurred such as opening doors.

Additionally, heat transfer increases and decreases with velocitychanges in forced convection or counter-flow systems, depending on massflow rate and total enthalpy transferred. Using the described method andapparatus, heat transfer may be precisely controlled at terminal heatexchangers in cooperation with temperature/density/SG changes of air andfluids for maximum effectiveness.

Other portions of a distribution system may reap the advantages of highvelocities to overcome such obstacles due to low flow coefficients andoverall high dynamic losses. Alternately, higher static pressure willcarry the air-fluid through longer straight sections and provide precisepressure application where needed.

Summary

The overall planned approach presented by the method and apparatus,which applies the key gradients in the correct measure where and whenneeded, will allow the conversion process of SP and Vp throughout agiven distribution system to preserve the utmost Total Pressure, thisall the while decreasing in the direction of flow. As a result, thiswill be considerably more than if it were squandered through neglectfuldesign and sensing considerations.

Additionally, evaluating this effect in exacting degree at variousportions of a distribution system will create lower horsepower demandand lower total power required to perform specific tasks at any giventime. High-pressure systems may always be needed for some applications,but achieving a tempered balance is one solution to fluid distributionproblems that ultimately create high demands on total system powerthrough overuse of static pressure gradients and misuse of dynamic flow.

Dual Damper Control Embodiment

To present a key example of how a primary mover and a terminal controldevice may work in conjunction for a desired effect, note FIG. 16,Series Operation 18, and FIG. 16A, Parallel Operation 19.

The primary mover 1 (or blower in this example) is equipped with a VFD(Variable Frequency Drive) or some other form of speed control 7. Drivenspeed of rotation is understood as being direct to flow-volume (CFM.) Inshort, fan rpm direct to flow, flow squared to pressures, and flow-frpmratios cubed to brake horsepower.

In this example, a known flow rate and Total Pressure as supplied by theblower 1 pass through the terminal device 3, less losses; these createdby overall pressure drop of the terminal device from inlet to outlet,length of run, flex fittings, and finally, terminal outlet diffusersdownstream of this. Coefficients and other tabulated factors aresupplied by the system database.

Let us theoretically assume that the pressure content of the TotalPressure produced by the fan is 50/50, 50 percent Velocity Pressure and50 percent Static Pressure and the primary mover 1 is operating at 50percent capacity (30 HERTZ,) these conditions to be understood as thenormal operating conditions, all dampers fully open and the system curvereflecting this design condition.

Suppose that the primary damper-actuator 3 were closed to 50 percent,noting that this degree of closure is not direct to pressure drop, asthis depends on the damper/terminal device 3 characteristics. For thisexample, we will assume that flow has also dropped 50 percent from itsprevious “wide open” condition and overall pressure has dropped toflow-squared, or 25 percent.

The desired effect would be to increase the Static Pressure content ofthe Total Pressure by creating an “artificial” system curve 5 whenthrottling the damper 3. The velocity portion of the equation has beensubstantially reduced and the remainder of the Total Pressure has beenconverted to static for the desired effect, whether this be to overcomemore length of run losses or some other specialized purpose.

Keeping in mind that some Total Pressure is lost fore of the system inthis process, the total system curve moves up and to the left along themover's curve. 11 FIG. 12A

If not interpreted correctly, the above action could be misconstrued asbeing an indicator of undue system restriction 5, or conversely, adversemover performance 11. One is contingent upon the other.

In this case, we are proceeding with the assumption that the mover andsystem's performance curves 11, 5 are known and firmly established. Ifone is known, the other may be established using said method andapparatus, as previously described.

Leakage losses will be indicated by any deviation of the system curve 5in the opposite direction from a firmly established starting point10—this down and to the right, along the mover's steady curve 11. FIG.12A. This issue is specifically addressed under leakage testerembodiment.

If a closed damper 3 in a given system 5, for example, were unknown,then a false system curve 5 would be plotted, not reflecting actual“full flow” conditions. However, in this example, the throttling of theprimary damper 3 is deliberately imposed to create a desired effect.Again, because Total Pressure loss occurs fore of the system due to thedamper's throttling, the frequency drive must ramp up to the appropriatelevel 7, increasing fan power used if the Total Pressure is to bemaintained aft of this primary damper 3; keeping in mind when blowerchanges are effected that the blower's curve 11 moves along the system'scurve 5 to its new driven speed of rotation. FIG. 12.

This data may also be viewed on the mover's wide open performance curveacross a full range of speeds, each being independent of the other whenheld constant, referring to FIGS. 6 and 6A.

To what degree this move is necessitated all depends on what effect isdesired and can be determined with high precision, based on percentageof content (SP and Vp of TP) and the degree to which the system curve 5strays from its original starting position or meets its target position,FIG. 12A. Also a factor, the degree to which the mover 1 must ramp up ordown 7 to accommodate the system 5, or maintain the desired operatingpoint 10 (FIG. 12) keeping in mind any fundamental changes which may beviewed on the Vectorial Display.

This may enable a user to manipulate the OP 10 in horizontal, vertical,or in any direction, the purpose of which may be to create desiredeffects in the system 5 and mover 11 without compromising one or theother elements, such as BHP, heat transfer, or flow-volume, while stillmaintaining necessary constants. Also, the fixed OP 10 may in itself bethe desired constant in a variable system 24 undergoing many changes.

If conditions at this point in the system 5 are acceptable, such asshort length of run and few fitting losses, then ramping up the VFD 7and increasing the power of the mover 1 may not be necessary to achievethe desired effect. Additionally, the degree to which the mover mustexert more power to maintain the desired pressure or flow rate is adirect reflection of how efficiently sized and fitted the connectedductwork is. Though now solved, this problem may have been avoidedentirely, however, if the described method and apparatus had been usedfrom origination in designing, selecting, and sizing the mover 1 andsystem 5.

Following the action of the primary damper 3, the secondary damper 18may then modulate to its minimum and maximum set parameters within thesepre-established conditions as required by the specific task at hand.FIG. 16.

As depicted in FIG. 16A, the parallel damper 19 and additional flowsource provide a cumulative velocity to traverse fitting and directionallosses, though the primary damper 3 may provide critical run leverage bygenerating Static Pressure in tandem with motor-drive speed control 7and, thus, maintaining adequate Total Pressure.

Generally, Parallel Operation 19, as demonstrated in FIG. 16A, isintended for a system 5 with excessive bends and fittings (Vpgradients.) It may also serve a function in Constant Pressureapplications, with mover 1, speed control 7, terminal devices 3, and allrelated system components working in tandem. Series Operation 18, asdemonstrated in FIG. 16, may be used in those systems 5 with longer runsand minimal fittings (SP gradients.) This arrangement may also serve afunction in Constant Volume applications, with mover, speed control,terminal devices, and all related system components working in tandem.

The method and apparatus will also plot TP/SP/Vp curves with the SP/Vpratio shown on display, as with any other embodiment of the same. Thiswill include the entire course of all moves or deviations from any prioroperating points 10.

Leakage Testing

A main concern in all ductwork construction, aside from being correctlysized and fitted to begin with, is leakage. In the past, leakagecharacteristics have been difficult to pin down in the practical world,as leakage testing at the outset of all projects is rarely everperformed, unless specified from the outset. The conditions are alsodemanding and stipulate that all the drop cut out fittings or alloutlet/inlet portions of the main duct be capped by section. Even thismethod is a faulty one, as most leakage occurs at fitting joints,terminals, and other “takeoff” points that are installed later in theduct construction process.

As a valid solution to current leak testing problems, the describedmethod and apparatus may be utilized to accurately distinguish whetherlosses and general deviations in a given system 5 are due to leakage,undue flow or undue restriction (improperly fitted or sized ductwork.)The versatile leakage tester embodiment of the method and apparatus maytake a variety of forms not limited to those described here. Theexamples presented here demonstrate leakage testing conducted with thefollowing: 1) a capped duct main section or some unknown vessel orenclosure 5. 2) a new or existing system 5 that has already been fitted.Results may be obtained with or without a known system 5 and OP 10, asshown in FIGS. 17 and 17A.

Additionally, the primary mover 1 and terminal (flow metering) device 3are recommended to be tested with method and apparatus of same, thoughthis is not necessary for adequate results in regards to existingmovers/systems.

In any case, leakage rate and quantity may be determined by variances inthe system curve 5 plotted against the primary mover 11 or the terminaldevice 11 that reflect relative increases in velocity and, conversely,decreases in static pressure; basically put, pressure loss due toleakage and more free flow as a result. Again, the starting point may bea known curve 5 established by the design engineer, or may begin atdefault settings supplied with the mover 1 and/or terminal device 3 fortheir recommended scope and range for optimal efficiency.

The default setting criteria will be based on known, pre-determinedfacts establishing which type of system 5 the selected mover 1 andterminal device 3 are best suited to for optimal efficiency. This willbe determined by reliable test results conducted under described methodand apparatus testing procedures for lab or field conditions ascircumstances permit.

To illustrate the general point of determining leakage, the effect onthe three-part curve would be the following: A system deviation wouldoccur from an established design OP 10. The total system 5 moves downand to the right. A percentile increase in the Vp gradient will benotable in particular. This may also be represented by a single vectorpointing down and to the right diagonally.

FIG. 17 depicts a capped main section 5 undergoing leakage testing.Terminal device damper shut-off 3 is used to bring the section to its SPrating and maintain this level. It is then able to measure quantitativevelocity passing through, per duct surface area, as a direct indicationof leakage. Its exact CFM amount and whether it is within acceptabletolerances can then be determined.

Note that the Vp must be converted to FPM units prior to actual CFM ofleakage being determined: FPM×Area=CFM. Also, the following duct data issupplied: Duct type, material, seal class, leakage class, pressureclass, design static pressure, airflow volume, surface area, airflowsurface factor, % predicted leakage versus actual measured. The FPMacross the total surface area determines the actual flow (CFM) ofleakage.

Sequence of operation: The mover 1 ramps up 7 or the terminal device 3closes its damper-actuator until static sensor input reaches the enteredvalue of the duct rating and stops. Once SP and Vp solitary curvesexperience level off, the exact percentage of Vp content is determinedand noted in sampled or real time. This figure is then converted to FPMunits across an adjusted area, this determined from only that sectionbeing isolated for testing. FPM=SQ. RT Vp×4005 for standard air. CFMleakage flow rate is established. For non-standard air, a densityadjustment is made: V=1096 SQ. RT. Vp/d.

FIG. 17 shows SP and Vp solitary curve displays 6 plotting level-offplateaus, where each gradient is required to remain constant undertesting conditions.

The above embodiment allows for convenient in-line leakage testing atany point in a distribution system 5 under control of same method andapparatus 25, from the primary mover 1 to any designated section 5 wherethere is a terminal device 3 fitted with damper control throughout asystem in entirety, whereas previously, crude orifice plates andcumbersome “clamp-on” leakage testers have been employed with enormouseffort and inconvenience, one capped section at a time.

Determining Volume of a Given Vessel or Enclosure

By metering a free flow rate and considering density of air or specificgravity of a fluid entering a vessel, the said method and apparatus maydetermine the interior volume of a given vessel or enclosure 5. FIG. 18.

First, the system curve 5 of the vessel/enclosure 5 may be establishedthrough precise, instant readings. Assuming a known terminal device 3 orflow-pressure station 2 connected thereto, the free flow rate continuesuntil build up of static resistance causes it to begin to cease. Thisexact point, wherein flow encounters maximum resistance—or the totalstatic power of the primary mover 1—will be marked as a cutoff point.The exact flow volume rate that passed the metering device will bederived from CFM units, after Vp is converted to FPM. Therefore, aninstant reading occurring at this cutoff point of 60 CFM, for example,will mean 60/60=1 cubic foot of interior volume inside of the vessel orenclosure.

Any flow characteristics beyond this pivotal point will be plotted andnoted as well. These may be interpreted as static and dynamic factorspresent after the vessel has been filled to its full interior volume, ormore indicatively, when the primary mover 1 has reached its total staticpower, less the total static drop of the metering device, less any Vpwhich may exist in the form of leakage leaving the vessel at a steadyrate.

Thus, a lesser, tapering off of dynamic flow may be measured andinterpreted as a leakage rate after the threshold of full volume hasbeen achieved. Static qualities may be noted as well, before and afterthe vessel has reached its full volume, depending on whethercompressible or non-compressible fluids are being used and what changesof fluid state may be occurring.

The method and apparatus embodiment may also be used for compressiblegases, fluids, or mixtures, given temperature/density/SG corrections.Also, the desired level of compression may be set by adjusting thesefigures after full volume of the vessel is achieved one time over. Thegas or fluid may be further compressed beyond this point withtemperatures, densities, specific gravities being precisely monitoredand set according to known characteristics of the gas/fluid/mixture orlevel of compression within the vessel.

A uni-directional valve, or shredder-type valve, such as those used incontainers of such gases or fluids may be employed to keep thecompression level constant and contained. If articulate control of thegas-fluid's passage into the container is desired, a fitting terminaldevice 3 similar to those previously discussed may be employed. Units ofmeasurement may be switched or converted, e.g., PSI, “Hg, metricequivalents, etc.

The above embodiment may be ideally suited to the same air-fluiddistribution system 5 for its refrigerant compression/expansion cycle,affording precise control of the mover (compressor) 1 and thermostaticexpansion valve, a terminal device 3 in itself. The compressors arenormally rotary-type or positive displacement movers, which are inclinedto be less responsive to pressure. This is precisely why adequatepressure control within the vessel containing the gases in changingstates can be highly beneficial to the refrigeration cycle, along withproperly timed movement or flow-rate. The method and apparatus providesthe means to control such a system with quantitative precision and exacttiming, which is crucial to the expansion and condensate cycle, as thistends to over or under shoot in current systems with wide dead bands,not allowing full heat exchange potential to be realized between theevaporative and condensate phases. Employing the method and apparatus insuch a manner avoids loss of and boosts optimal heat exchangeeffectiveness within this system itself, which may simply be viewed asan additional distribution system with terminal (valvic) control and amover of one form or another.

The above function of the method and apparatus may apply to any coolingor heating system condensate, expansion, absorption, or other cycle,with or without a change of state, involving air-fluid mechanicsincluding gases, mixtures, and thermal dynamics as described in anyform, number, or combination.

Flow-Head (or Flow-Pressure) Stability

Due to a condition known as flow-head instability, a piping distributionsystem 5 may tend to cause automatic or sensor-motor controls to hunt inan adverse cycle, short-circuiting the distribution system and causingincorrect sensor feedback. As a result, automatic controls operate in asmall part of their range. This condition occurs mainly in hydronicsdistribution systems in which three-way valve control is used on primaryor secondary circuits. These circuits often have improperly sizeddifferential valve capacities or flow coefficients assigned to them(Cv's or K factors in air and like systems) across an appropriate rangeof movement between full flow to full bypass of a main or terminalcircuit. In open hydronics systems, elevation and the location of thesebypass lines also impacts this effect.

Among other things, system flow-head variation can cause chiller shortcycling, diminished heat exchange effectiveness at primary and/orterminal heat exchange devices, such as cooling or heating coils. It mayalso create other load imbalance problems, such as load shifting or loadsharing.

Use of the described method and apparatus increases and improves thecharacteristics of this critical range of valve movement between fullflow to full bypass.

Range of Mover-System Loading and Unloading

During normal operation, loading and unloading of terminal units 3 withincreases and decreases in system demand alter the OP (Operating Point)10 of the system 5. Terminal devices may include but not be limited to:valves, heat exchange terminals 8, and any solid-state components, whichaffect airside, waterside, heat-flow, etc.

Appropriate boundaries may be established for pumping or movingequipment that represent parameters of possible loads. FIG. 35. Theseparameters 23 are set by the diverse loading and unloading of terminalunits/devices 3 within the system 5 and are largely tied to the systemdiversity 22. This designated region, as best established by said methodand apparatus, outlines the scope of pumping or moving energy that canbe conserved when the mover speed is variable 7. This area is greatlyincreased in scope and breadth by the method and apparatus, namely butnot solely due to improved flow-head stability and its ability toincrease the margin, size and scope of diversity 22. Specifically, thearea of mover and terminal device operation 24 is “flattened” and“widened,” an area where modulating valves 3 or terminal devices 3operate best. The other key benefits:

BHP demand and total power required is lessened, system resistance islessened, static efficiency is increased. Note FIG. 35, crosshatchedareas. Additionally, this support is furthered by its individualbreakdown of TP where and when needed, and as specifically demanded byterminal or in-line components (valves, etc.) with all of theirpre-determined characteristics therewith. In what number and to whatdegree the valve demand is required is also tempered by the method andapparatus. The latter effects may also be established with the methodand apparatus as previously stated or otherwise.

Also referring to FIG. 35, independent system curves or independentheads are plotted to illustrate and define system constants against anysystem variation as produced by loading/unloading within the variablesystem 24, thermal or mechanical. As a result, the pressure (head) orflow capacity may be arbitrarily adjusted to either increase systempressure or increase system flow and place the operating point 10 wherebest suited or desired. Note that the relationship need not be inverselyrelated, wherein one decreases as the other increases, as these may alsobe viewed and controlled as independent relationships and manipulatedfor useful purposes by way of the method and apparatus. Thus, the use ofthe method and apparatus allows one to alter the system characteristics5 independently, and/or alter the mover characteristics 11 independentlyand, ultimately, reconfigure the operating point 10 or juxtapose the newoperating point 10 with a previous one. Altering mover characteristics11, for example, may be accomplished by specific changes to RPM, drivechanges or, in the case of pumps, changed impeller diameters as variedin direct proportion to flow. Additionally, any relationship relating toflow-pressure, BHP, and affinity laws present enough information toeither extrapolate or, preferably, interpolate performance projections.The described method and apparatus provides the best means for anaccurate interpolation of performance data or any relevant data and forproviding equipment recommendations. Altering system characteristics 5,for example, may be accomplished by fitting changes to the distributionsystem entailing all tabulated and database references as previouslynoted.

In hydronics systems, the minimum differential head constant shown inFIG. 35 is presented as a constant derived from the distributionsystem's critical run 5 and terminal device 3 at full demand or fullcapacity. The total vertical difference of the system curve extremesrepresents the total system losses (main circuits and all terminals)from minimum to maximum demand operation. The center vertical linerepresents the pressure/head constant delineated by a vertical move topto bottom only. The solid system line crossing the center in FIG. 35represents where a constant volume system (non-variable or symmetricallyloaded) would operate, if it were thought of as such a system. You mightsay that it is tempered precisely between the two outer parametersshown. Dotted steep and flat curve lines delineated the parameters oftotal system operation.

The crosshatched areas shown in FIG. 35 represent the possibilities andconstraints of variable system operation 24 with a variable mover 7attached. Mover efficiency and affinity relationships may also beconsidered and the operating point 10 deliberately placed in effectiveareas by the method and apparatus. The parameters set by the HI and LOcurve areas 23 may provide an exact window of mover rpm control 11 orterminal valve modulation control 11, whether interpolated from anexisting system or specifically designed using the method and apparatusfrom origination. Vectors may better illustrate this and other criticalareas to avoid a crowded image. Their immediate length and directiondemarcate exact system operation and boundaries. They also identify theoperative element at hand as previously noted. Once these designatedboundaries are firmly defined and an OP placed, the method and apparatusmay refer to its database to determine exactly appropriated equipment,or closest stock equivalents currently available, i.e., movers andfittings for the fully designed system.

In most hydronics systems with standard water, velocity may be negatedfor practical purposes, and so TP=SP. In an air system, the parametersshown in FIG. 35 are outlined through the TP, Vp, and SP breakdown.Similarly, the operating parameters for an air system can be determinedby the critical run and terminal device, noting that in this case theparameters are not determined only by a differential static ordifferential head pressure. A hydronics system has return pipingfriction losses plus the terminal device (valve) total drop that areaccounted for in a closed loop system. Water must return in a closedpiping system, where air is delivered to an open space and converted to100% velocity at some point. Despite this interruption between avariable supply air distribution terminal and its ducted or non-ductedreturn air plenum, the starting datum parameter for an air system issimilarly set by the critical run and its maximum demand, consideringtotal, static, and velocity pressures. Conversely, its minimum demandposition sets the low demand parameter and a variable mover 7 ramps downto track with the variable system 24 with open or closed loop control.This action, however, changes the system curve 5 considerably and is themain reason current VAV systems have trouble operating in lower demandsituations, further compounded by the ramp down and Total Pressure lossof the mover 1 based on current sensor use and placement, which clearlydoes not work. The complete landscape of the distribution systemchanges. Its total dynamics change, even the critical run or runs maychange from the maximum demand position. The prescribed mover's reactionto the “new” system changes as well. The method and apparatus addressesthese problems by identifying and evaluating these critical runs with orwithout system diversity, mapping, changing runs, etc., among othermeans described.

In basic terms, Total Pressure conversion occurs with motorized damper,terminal device 3 repositioning, change of flow cross-sectional areas,k-factors, etc. The other counter-productive variable in current systemsis the mover variable 7. The variable speed mover or older vortex systemtracks down as dictated by incorrect static sensing and, consequently,lowers Total fan pressure 20 indiscriminately, particularly on thesuction side—its first casualty, as noted previously. Current staticpressure sensing methods and their described limitations cannot copewith these changes. The method and apparatus addresses this problem asdescribed.

Key Contrasts of the Differential Pressure/Head Constant

In the case of an air system, the differential pressure constant shownin FIG. 35 may be replaced by a Total External Pressure 21, unlike adifferential head in a hydronics system. Specifically, this accounts forall supply air and return air ducting external to the prime mover 1 andlosses needed to be overcome by total mover gains—in maximum totalsystem demand 23. This denotation is chosen in light of current packagedsystems, which include blowers, coils, filter sections, modules, in-linedevices, etc., as noted previously. Again, note the TEP 21 as delineatedin FIG. 3, and as distinguished from prior understanding with the addedbreakdown of TP into SP and Vp. Referring again to System Effect losses,particularly on the suction side of packaged movers or packaged “units”as currently understood, there is a special consideration for thesuction pressure as viewed independently, due to outdoor air and returnair rates, which must be maintained within tolerances in a variable airvolume (and pressure) system commonly prone to suction pressure lossesas mentioned previously. Such deficiencies, in turn, contribute tovariable air systems' failure to achieve adequate outdoor air rates and,moreover, return air rates, which recover cooling load. Thus, the UnitTotal External Pressure 21 as here described is the differentialpressure constant (vertical) viewed in the crosshatched operating zonein FIG. 35. Additionally, the method and apparatus can re-plot theseparameters for minimum operation due to reasons previously described,including maintaining outdoor air rates. Above all, the parameters andcomplete characteristics of mover-system operation will always beappropriately tracked throughout all degrees of system or terminaldevice ranging at all times and conditions of such operation, aspreviously described. Namely, the key consideration will be Vp in an airsystem and, above all, the conversion of TP into VP and SP elements,which is not a problem when referring to a standard hydronics system,where TP=SP. Thus, the operating zone 24 shown in FIG. 35 is delineatedseparately and at separate mover and valve constants 11 for both minimumand maximum operation of air terminal devices 3, unlike in a standardhydronics system, where this may or may not be deemed necessary.

In contrast, the parameters shown in FIG. 35 indicate total pressureloss and gain required for a hydronics distribution system's supply andreturn mains. In an open hydronics system, return head is either negatedby elevation or provided for by additional pumping power if suction liftis required (usually avoided.) One key difference between a hydronicssystem and an air system when viewing FIG. 35 is that flow increases ashead lowers in a hydronics system, where flow decreases as pressurelowers in an air system, at least where performance curves and projectedaffinity relationships are concerned. These are the commonextrapolations as currently understood when viewing performance curvessupplied by a manufacturer. The method and apparatus addresses thisproblem as previously described. In any case, the purely functionalimage in FIG. 35 simply “flip-flops” where both air or hydronics systemsand their min/max or “total” parameters are concerned. Separate,detailed images for a pump or a blower curve would be provided on adetailed display 6, since BHP, RPM, and efficiency markings are quitedifferent for the two. Again, the key exception to the above problem isalready pre-determined by the method and apparatus as previouslydescribed. And that is that these characteristics may be misleading in asystem 5 where, for example, static increases occur due to unduerestriction, rather than increases in flow by previously thoughtperformance prediction. This is sometimes referred to as an “artificial”change in the system 5, such as when a discharge balancing damper 3 isthrottled to increase pump head for desired results.

Steep curved pumps or movers 1 do not respond well to valve differentialhead. One goal is to minimize the valve pressure ratio increase betweenthe mover 1 and the valve or terminal device 3, or maintain the UnitTotal External Pressure 21 in air systems. Through maintaining optimalflow-head stability and previously described use of the method andapparatus, the method and apparatus minimizes the valve pressure ratioincrease between the mover 1 and valves or terminal/in-line devices 3within a distribution system 5. The method and apparatus makes possiblea wider range of load 24 and, thus, a flatter operating curve forterminal equipment. This can also permit the use of steeper curvedmovers 1 to maximize their limited range 24 within distribution systems5, or vice versa; steeper curved systems 5 may be paired with flattermovers 1. It then follows from the above and previous description thatthe method and apparatus allows automatic control valves 3 and allvariables within the distribution system or sub-system to operate in agreater, more effective range 24.

Variable Air Volume Systems

Because of the complexities of a VAV system with two or more terminalbranches and a plurality of terminal VAV devices in constant modulation,it becomes necessary to address the performance of the primary mover, aswell as the system whole and all aspects of the dynamics involved. Thesystem curve independent pressure constant and parameters, as depictedin FIG. 23 illustrate the distinct window for VAV or variable hydronicssystem operation. During VAV operation (24), terminal branch dynamicschange the total and terminal system (5). In doing so, the “criticalrun” or “critical path” must be established and also tracked by thecontrol system, as the route of this path may also change and beassigned from one terminal device to another under differing conditionsof operation. The described method addresses this problem, firstly byestablishing the main critical run terminal from terminal device sensorinput (4) and sorting each run (5) and device (3) in the system fromleast to most critical in total sensor value, with the least criticalbeing assigned to the margin for diversity (22), these placed in eithertheir minimum or closed positions. FIG. 20.

The constant established in FIG. 23 outlines all the necessaryboundaries for the variable volume system and where to best place theoperating point for the given mover and valve constants (11) at anyspeed or position. The method proceeds as follows: The main critical runis established with all dampers indexed to their maximum positions (HI)at their maximum mover driven RPM (11) required to achieve theprescribed flow rate with the given system profile as set here. 2) Acritical run is established in minimum position (LO) for the minimum orlowest demand operating parameter. This repositioning is primarily dueto the velocity factor, wherein flow coefficients (dynamic) factorschange significantly with valve throttling, particularly in avelocity-based system. All ranges between parameters are also trackedwhen runs are sorted from least to most critical within the establishedboundaries (24).

Series Operation

Using embodiments described in series and parallel damper functions (18,19), the control method utilizes automated controls to effect whatevermain or terminal damper changes are necessary to maintain the operatingpoint (10) where designated as terminal devices (3) and the system whole(5) modulate. For example, if a sub-system change such as would becaused by an opening valve on a terminal branch alters the total systemcurve (5) and rides the mover curve (11) to cause more sensed flow(Vp)—down and to the right—the main damper control, FIG. 16 (3) canrespond by throttling down to create an artificial static pressureincrease to meet and maintain the deviated operating point (10). Anincrease in flow signifies a decrease in pressure by conversion. Forcreating leverage in reaching critical runs or increasing the staticpressure in a system, main damper control may be manipulated to producestatic increase, as described in series damper operation. FIG. 16.

Though Total Pressure may be lost on the whole as well, the method andapparatus keeps this at a minimum through its key functions. Again,Total loss occurs in direction of flow or through System Effect lossesnever recovered at any point in the system (5). Subsequently, as TotalPressure is lost or gained, a function of the method causes the variablemover (1) to increase or decrease rotational speed (7) to adjust thismeasure in exact proportion to what was lost or gained, in this exampleusing its Total Pressure sensors (13). Alternatively, the other sensors:SP, Vp (14, 15) may be used as well to adjust x or y valuesindependently. The affinity relationship dictating that rpm is squaredto all deducted pressures and cubed to BHP governs this calculatingfunction. The specified content percentages (% SP % Vp of TP) willdetermine these net pressure losses and in what measure to effectmotorized controls.

The final goal or step of this function is to return the Total Systemcurve (5) to its original point of operation (10) along the mover orvalve constant (11) and, ultimately, maintain optimal flow-pressurestability in the system whole (5). Increased diversity potential (22) inthe system by way of the method and apparatus also provides a wider,more effective range for damper-valve (3) modulation and, thus, greateradded stability. The above functions may be alternately achieved byseries blower operation FIG. 14C or any additional flow source inseries.

Parallel Operation

Similarly, if a static increase (SP) occurs and, thus, a dynamicdecrease, then parallel operation (17, 19) can take effect as describedin embodiments, whether through auxiliary fan power—a secondary mover inparallel (17), a relief opening, a bypass, or a secondary source of flowin parallel. FIG. 16A

The above description also applies to terminal devices (3) in series orparallel operation (18, 19) with secondary mover power, FIGS. 15C and15D, to create gains where losses of one form or another occur or,alternately, create dampering losses where gains of one form or anotheroccur. FIG. 16, 16A

Among other influential factors, the above functions with “best mode ofoperation” being variable system function contribute to optimalflow-pressure or flow-head stability. This process can maintain totaland/or terminal system flow-pressure stability and may track with anyand all system or sub-system changes (5). More specifically, all moverand system components can track to fully articulate system requirementswith or without auxiliary flow-pressure variables, e.g., from secondary,tertiary movers, other sources, etc. One key purpose serves the functionof fill and relief valves or unidirectional valves, where flow and/orpressure are compensated or dispensated to maintain flow-pressurestability.

Using the above relationships through embodiments as described, affinityperformance “projections” need not be followed as the method andapparatus follows its own sensor logic based in a real, “as-built”system as really sensed. Above all, all mover-system relationships areviewed and controlled in the context of correctly coordinatedperformance curves, as is the only valid means to proceed with accurateperformance prediction.

Support of the method is strengthened by the fact that it is a deductiveand not an inductive process based on Total, Velocity, and StaticPressures (13, 15, 14) being established independently through most toleast accurate sensing. Static being the acknowledged least accuratefield sensing method, it will always be accurately deducted from TotalPower or Total Wattage and Velocity factors, closed loop or closedcircuit differentials with an absolute value. As previously noted,however, Total and Static values may have atmospheric references or mustbe corrected for this and other internal losses as accounted for by saidmethod through BHP evaluation.

In any case, there will be at least three or more verification points,which will include the Total Power (voltage and amperage) deduction ofBHP, considered as another of the most accurate data points in fieldmeasurement, along with RPM and a multi-point velocity reading toestablish CFM flow rate, as with a pitot tube. The total wattage of themotor powered mover and the corrected BHP as derived from currentreadings is also represented by the “Mover Total Pressure,” a keycomponent of the apparatus, where voltage and amperage parallel staticpressure and velocity pressure, respectively.

Additionally, this process can be described as a deductive method ofTotal Pressure and Total Power, namely where corrected BHP is concerned.Unknowns are determined based on interpolation between two or morefirmly established knowns and step functions either compensate ordispensate pressure gradients as needed or demanded by a distributionsystem.

The data points as described in “Initial Point of System Operation” alsofurther support a starting point of system operation and continuedtracked operation. Any unknowns that remain are further crosschecked bycurrent power factors and negated or supported by those knowns mostfirmly established. Under lab testing conditions in a controlledenvironment, these performance characteristics will also be furthersupported by the described method and apparatus and carried into thefield with greater certainty.

Through variable mover-system operation, the “best mode of operation,”and critical path mapping, it follows that diversity potential in thedistribution system is increased by way of the method and apparatus,thus providing a wider, more effective range for damper-valve modulationand greater stability for the system whole.

The many functions and embodiments of the method and apparatus shall notbe limited to those described here in any form, number, or combination,nor to any industry, field, art, or science that may employ such meansto further its advancement through utilization of the method andapparatus. Such parallels to other arts, which the described method andapparatus stands to advance, may include: electronics or electriccurrent flow, where electromotive forces (voltage and amperage) areconcerned, semiconductor operation, signal modulation (frequency andamplitude) transmission and reception, telecommunications, informationtransfer, storage and retrieval—computerized or otherwise. Use of themethod and apparatus stands to improve overall engine operation,transmission, power, and performance, including BHP to torquerelationships; any variety of gas, fluid, or mixtures and theirmovement, distribution, or containment, including hydraulic machines orthose otherwise pressurized below or above atmosphere. Use of the methodand apparatus may advance the economic principle of supply and demandand currency flow. Biologically or mechanically, the use of the methodand apparatus may advance cardiological functions such as cardio(aerobic) and anaerobic (force and resistance) heart and muscleoperation, where circulatory or other such biological or mechanicalvascular systems are concerned. The method and apparatus may pertain topulsation, modulation, or pulse-width modulation in place of rotationfor movers that do not rotate or other solid-state machines notutilizing moving parts. Finally, the principle operation of the methodand apparatus may be reduced to the prime concepts of kinetic energy andpotential energy.

1. A method for engaging building Smoke Mode Operation with airdistribution systems wherein the Outdoor Air primary air damper isopened to 100% and the Return Air secondary air damper is closed to 0%for smoke mode purge operation, thus injecting 100% Outdoor Air primaryair into a vessel or building envelope; applying appropriate ACH (AirChanges per Hour) required to dilute total air of smoke content within agiven period of time; applying mover power (7) as needed to maintain theoperating conditions (10) as varied or fixed; and maintaining necessarysystem total constancy (5).
 2. A method in accordance with claim 1 forengaging building Smoke Mode Operation with air distribution systemswherein building exhaust distribution systems are activated to provideexhaust air movement relative to atmosphere for smoke evacuation from avessel or building envelope in coordination with primary air injection;applying appropriate ACH (Air Changes per Hour) required to evacuatetotal air of smoke content within a given period of time; replacingtotal air content with adequate primary air or makeup air changes;maintaining a ratio of a minimum of 80% makeup air to 100% exhaustedair; applying mover power (7) as needed to maintain the operatingconditions (10) as varied or fixed; and maintaining necessary systemtotal constancy (5).
 3. The method of claim 2 wherein VAV (Variable AirVolume) terminals downstream of the system are indexed to their smokemode sequence of operation, wherein the terminals produce adequate airchanges per zones served on a constant volume basis;
 4. The method ofclaim 2 wherein all main branch or zone dampers are indexed to theirsmoke mode sequence of operation, wherein the zone delineations produceadequate air changes per zone on a constant volume basis.
 5. A systemfor engaging air handler smoke mode operation wherein a two-way andmodulating damper actuator placed in bypass separates the RA from the EAplenum, wherein an integrated exhaust system and secondary mover isisolated from the primary air handling system; wherein exhaust airflowis diverted to atmosphere; wherein primary outdoor air content is 100%;and wherein return airflow is not recycled.
 6. The system of claim 5 or7 wherein if dry bulb immersion sensors situated in the RA or EA plenumsindicate sensible heat to be approaching 100% of the total heat content,a warning indication of smoke or fire may be relayed.
 7. A system formixing airstreams and adjusting percentages of OA/RA (Outdoor Air/ReturnAir) content in air distribution systems in accordance with claim 5,which comprises a ducted mixing box housing frame fitted with dualdamper control and flow sensing stations in parallel operation; anactuation means of modulating open or closed, allowing both air streamsto be throttled and mixed in particular proportions of Outdoor Airprimary air quantity and Return Air secondary air quantity at operatingconditions set and maintained as per flow-pressure monitor sensor input;a separate, effective ducting of outdoor air and return air channelingseparated air streams into the mixing chamber; a mixing chamber allowingair streams to be mixed where air is not stratified; multi-point dry andwet bulb temperature sensors placed in each individual air stream andwithin the mixing chamber, where air is not stratified; an integratedexhaust and return plenum separated by a two-way bypass damperconnection; a sensor relay alarm means triggering the mixing box, maindamper control, and all downstream zone damper sequencing for smoke modeoperation.